Siemens Milltronics SF 500 Instruction Manual

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Page 1

Instruction Manual September 2003

milltronics

SF 500

Page 2

Safety Guidelines

Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected equipment. These warning notices are accompanied by a clarification of the level of caution to be observed.

Qualified Personnel

This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install and operate this equipment in accordance with established safety practices and standards.

Warning: This product can only function properly and safely if it is correctly transported,

stored, installed, set up, operated, and maintained.

Note: Always use product in accordance with specifications.

Disclaimer of Liability

This document is available in bound version and in electronic version. We encourage users to purchase authorized bound manuals, or to view electronic versions as designed and authored by Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. will not be responsible for the contents of partial or whole reproductions of either bound or electronic versions.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.

Contact SMPI Techni cal Publications at the following address:

Technical Publications Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, Ontario, Canada, K9J 7B1 Email: techpubs@siemens-milltronics.com

While we have verified the contents of this manual for agreement with the instrumentation described, variations remain possible. Thus we cannot guarantee full agreement. The contents of this manual are regularly reviewed and corrections are included in subsequent editions. We welcome all suggestions for improvement.

Technical data subject to change.

For the library of SMPI instruction manuals, visit our Web site: www.siemens-milltronics.com

Page 3

Table of Contents

Milltronics SF 500 ...............................................................................................................1

Milltronics SF 500 features .........................................................................................................1

The Manual ...............................................................................................................................................2

Specifications ......................................................................................................................3

Installation ...........................................................................................................................6

Dimensions ...............................................................................................................................................6

Layout ........................................................................................................................................................7

Software Updates ...................................................................................................................................8

Interconnection ........................................................................................................................................9

System Diagram ...........................................................................................................................9

Flowmeter ...............................................................................................................................................10

One Load Cell ...............................................................................................................................10

Two Load Cell ...............................................................................................................................10

LVDT ................................................................................................................................................ 11

Auxiliary Inputs .....................................................................................................................................12

Auto Zero .................................................................................................................................................12

RS-232 (Port 1) ........................................................................................................................................12

Printers ...........................................................................................................................................12

Computers and Modems ...........................................................................................................13

RS-485 (Port 2) ........................................................................................................................................13

Daisy Chain ...................................................................................................................................13

Terminal Device ............................................................................................................................13

Remote Totalizer ....................................................................................................................................14

Relay Output ...........................................................................................................................................15

Power Connections ..............................................................................................................................15

mA I/O Board ..........................................................................................................................................16

Installing/Replacing the Memory Back-up Battery ......................................................................16

Installing Optional Plug-in Boards ....................................................................................................17

To Install a Plug-in Board ..........................................................................................................17

Table of Contents

Modes of Operation ..........................................................................................................18

Display and Keypad ..............................................................................................................................18

RUN Mode ..............................................................................................................................................20

PROGRAM Mode ..................................................................................................................................20

PROGRAM Mode Display .........................................................................................................20

Entering PROGRAM mode ........................................................................................................21

Start Up .......................................................................................................... .....................23

Power Up .......................................................................................................................................23

Programming ................................................................................................................................23

Load Cell Balancing ..............................................................................................................................25

Typical two load cell flowmeter ...............................................................................................25

Zero Calibration ...........................................................................................................................28

Span Calibration ..........................................................................................................................28

RUN Mode ....................................................................................................................................29

Recalibration .....................................................................................................................30

Page 4

Material Tests ........................................................................................................................................30

% Change ......................................................................................................................................30

Material Test .................................................................................................................................32

Design Changes .....................................................................................................................................33

Recalibration ...........................................................................................................................................33

Routine Zero .................................................................................................................................33

Initial Zero .....................................................................................................................................34

Table of Contents

Direct Zero ....................................................................................................................................35

Auto Zero .......................................................................................................................................35

Routine Span ................................................................................................................................36

Initial Span ....................................................................................................................................37

Direct Span ...................................................................................................................................37

Multispan ......................................................................................................................................38

On-line Calibration ................................................................................................................................41

Factoring ..................................................................................................................................................45

Linearization ...........................................................................................................................................46

Operation ................ ............................... ................................. ............................... .............49

Rate Sensing ..........................................................................................................................................49

Damping ...................................................................................................................................................49

mA I/O (0/4-20 mA) ................................................................................................................................49

Output .............................................................................................................................................49

Input ................................................................................................................................................50

Relay Output ...........................................................................................................................................50

Totalization ..............................................................................................................................................51

PID Control ............................................................................................................ .............53

Hardware .................................................................................................................................................53

Connections ............................................................................................................................................53

Setpoint Controller – Rate Control ..........................................................................................54

Setpoint Controller – Rate and Additive Control .................................................................55

Setpoint Controller – Master/Slave Control .........................................................................56

SF 500 - Master ...........................................................................................................................57

SF 500 - Slave ...............................................................................................................................57

Setup and Tuning ...................................................................................................................................58

Proportional Control (Gain), P ..................................................................................................58

Integral Control (Automatic Reset), I ......................................................................................58

Derivative Control (Pre-Act or Rate), D ..................................................................................59

Feed Forward Control, F ............................................................................................................59

PID Setup and Tuning ...........................................................................................................................60

Initial Start Up ..............................................................................................................................60

Programming ..........................................................................................................................................63

Batching .......................... ...... ...... ......... ...... ...... ...... ....... ........ ...... ...... ....... ........ ...... .............66

Connections ............................................................................................................................................66

Typical Ladder Logic ...................................................................................................................66

Programming ..........................................................................................................................................67

Operation .................................................................................................................................................68

Pre-act Function ..........................................................................................................................68

Communications ......... ................................................ ............................................. .........69

SF 500 and SmartLinx® .......................................................................................................................70

Page 5

Connection ..............................................................................................................................................70

Wiring Guidelines ........................................................................................................................70

Configuring Communication Ports ....................................................................................................71

P770 Serial protocols ..................................................................................................................71

P771 Protocol address ................................................................................................................72

P772 Baud Rate ............................................................................................................................72

P773 Parity .....................................................................................................................................72

P774 Data bits ...............................................................................................................................73

P775 Stop bits ...............................................................................................................................73

P778 Modem attached ...............................................................................................................73

P779 Modem idle time ...............................................................................................................74

P780 RS-232 Transmission interval .........................................................................................74

P781 Data message ....................................................................................................................75

Dolphin Protocol ....................................................................................................................................76

Dolphin Plus Screen Shot ..........................................................................................................76

Modbus RTU/ASCII Protocol ..............................................................................................................77

How Modbus Works ...................................................................................................................77

Modbus RTU vs. ASCII ...............................................................................................................77

Modbus Format ............................................................................................................................78

Modbus Register Map ...............................................................................................................78

Modbus Register Map (cont’d) ................................................................................................80

Modems .........................................................................................................................................88

Error Handling ..............................................................................................................................90

Parameters ....................... ............................... ............................... ....................................92

Start Up (P001 to P017) ........................................................................................................................92

Relay/Alarm Function (P100 - P117) ..................................................................................................95

mA I/O Parameters (P200 - P220) ......................................................................................................98

Calibration Parameters (P295 – 360) .............................................................................................. 102

On-line Calibration Options (P355 to P358) .................................................................................. 103

Linearization Parameters (P390 - P392) ........................................................................................ 106

Proportional Integral Derivative (PID) Control Parameters (P400 – P419) ........................... 106

Batch Control (P560 – P568) ............................................................................................................. 109

Totalization (P619 - P648) ................................................................................................................... 111

Communication (P750 - P799) ...........................................................................................................114

Test and Diagnostic (P900 - P951) ...................................................................................................115

Table of Contents

Troubleshooting ............................................................................................................... 118

Common Problems Chart ........................................................................................................118

General-Communications .......................................................................................................119

Glossary .............. ............................... ................................. ............................... ...............121

iii

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Table of Contents

Page 7

Milltronics SF 500

Note: The Milltronics SF 500 is to be used only in the manner outlined in this

instruction manual.

The Milltronics SF 500 is a full-feature integrator for use with solids flowmeters. The SF 500 processes the signal from the flowmeter and calculates values for the rate of material flow and totalization. These values are displayed on the local LCD, or output in the form of analog mA, alarm relay, or remote totalization.

Milltronics SF 500 features

The SF 500 is programmable

• Two remote totalizer contacts

• Five programmable relays

• Five programmable discrete inputs

• One programmable isolated mA output for rate (standard)

• Two programmable isolated mA input, for PID control

• Two programmable isolated mA output for rate, PID control, or on-line calibration

The SF 500 is flexible

• Rate linearization

•Auto zero

• PID* control

• Batch control

• Multispan operation

• On-line calibration

* PID and on-line calibration control requires the optional mA I/O board.

The SF 500 can communicate

There are three communication ports on the SF 500, as standard. Use the two RS-232 ports for Milltronics Dolphin Plus and Modbus protocol. Link the RS-485 port to either a PLC or a computer. The SF 500 also supports Siemens Milltronics SmartLinx® and networks with popular industrial communication systems.

Introduction

The SF 500 is upgradeable

Enhance its basic features with the following:

•mA I/O board

• SmartLinx module

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 1

Page 8

The Manual

It is essential that this manual be referred to for proper installation and operation of your SF 500 solids flowmeter integrator. As the SF 500 must be connected to a solids flowmeter, refer to the flowmeter’s manual as well.

The manual is designed to help you get the most out of your SF 500, and it provides information on the following:

• How to install the unit

• How to program the unit

• How to operate the keypad

and read the display

• How to do an initial Start Up

• How to optimize and

maintain accurate operation of the unit

Introduction

If you have any questions, comments, or suggestions about the manual contents, please email us at techpubs@siemens-milltronics.com.

For the complete library of Siemens Milltronics manuals, go to www.siemens-milltronics.com

• Outline diagrams

• Wiring diagrams

• Parameter values

• Parameter uses

• Modbus register mapping

• Modem configuration

Page 2 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 9

Specifications

Power

• 100/115/200/230 V ac ±15%, 50/60 Hz, 31 VA

• fuse, FU1 2AG, Slo Blo, 2 A, 250 V or equivalent

Application

• compatible with Siemens Milltronics solids flowmeters or equivalent 1 or 2 load cell flowmeters

• compatible with LVDT equipped solids flowmeters, with use of optional interface board

Accuracy

• 0.1% of full scale

Resolution

• 0.02% of full scale

Environmental

• location: indoor / outdoor

• altitude: 2000 m max

• ambient temperature: -20 to 50°C (-5 to 122°F)

• relative humidity: suitable for outdoor (Type 4X / NEMA 4X /IP65 enclosure)

• Installation category: II

• pollution degree: 4

Enclosure

• Type 4X / NEMA 4X / IP65

• 285 mm W x 209 mm H x 92 mm D (11.2” W x 8.2” H x 3.6” D)

• polycarbonate

Programming

• via local keypad and/or Dolphin Plus interface

Display

• illuminated 5 x 7 dot matrix liquid crystal display with 2 lines of 40 characters each

Memory

• program stored in non-volatile FLASH ROM, upgradable via Dolphin Plus interface

• parameters stored in battery backed RAM. The battery is 3V NEDA 5003LC or

equivalent, nominal 5 year life

Specifications

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 3

Page 10

Specifications

Inputs

• load cell/LVDT Conditioning Card:

0 - 45 mV dc per load cell/LVDT Conditioning Card

• auto zero: dry contact from external device

• mA see optional mA I/O board

• auxiliary: 5 discrete inputs for external contacts, each

programmable for either display scrolling, totalizer 1 reset, zero, span, multispan, print, batch reset, or PID function.

Outputs

• mA: - 1 programmable 0/4 - 20 mA, for rate, for rate output

- optically isolated

- 0.1% of 20 mA resolution

- 750 Ω load max

- see optional mA I/O board

• load cell/LVDT Conditioning Card:

10 Vdc compensated excitation for LVDT Conditioning Card or strain gauge type load cells, 2 cells max, 150 mA max

• remote totalizer 1: - contact closure 10 - 300 ms duration

- open collector switch rated 30 Vdc, 100 mA max

• remote totalizer 2: - contact closure 10 - 300 ms duration

- open collector switch rated 240 Vac/dc, 100 mA max

• relay output: 5 alarm/control relays, 1 form 'A' SPST relay contact per

relay, rated 5 A at 250 Vac, non-inductive

Communications

•two RS-232 ports

• one RS-485 port

• SmartLinx

compatible (see

Options

on page 5)

Cable

• one load cell/LVDT:

non-sensing: Belden 8404, 4 wire shielded, 20 AWG or equivalent,

150 m (500 ft.) max

sensing: Belden 9260, 6 wire shielded, 20 AWG or equivalent,

300 m (1000 ft.) max

• two load cells:

non-sensing: Belden 9260, 6 wire shielded, 20 AWG or equivalent

150 m (500 ft.) max

sensing: Belden 8418, 8 wire shielded, 20 AWG or equivalent,

300 m (1000 ft.) max

Page 4 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 11

• auto zero: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m

(1000 ft.) max

• remote total: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m

(1000 ft.) max

Options

• Dolphin Plus: Siemens Milltronics Windows®based software interface

(refer to associated product documentation)

• SmartLinx

•mA I/O board:

• output supply: unregulated, isolated 24 Vdc at 50 mA, short circuit

• LVDT interface card: for interface with LVDT solids flowmeters (separately

® Modules: protocol specific modules for interface with popular

industrial communications systems (refer to associated product documentation)

inputs: - 2 programmable 0/4 – 20 mA for PID, control optically isolated

- 0.1% of 20 mA resolution

- 200 Ω input impedance

outputs: - 2 programmable 0/4 – 20 mA for PID control or rate

- optically isolated

- 0.1% of 20 mA resolution

- 750 Ω load max

protected

mounted)

Specifications

Weight

• 2.6 kg (5.7 lbs.)

Approvals

•CE*, CSA

*EMC performance available upon request.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 5

NRTL/C

Page 12

Installation

209

Notes:

• Installation shall only be performed by qualified personnel and in accordance with local governing regulations.

• This product is susceptible to electrostatic shock. Follow proper grounding procedures.

Dimensions

16 mm

(0.6")

(8.2")

172 mm

(6.8”)

lid screws

(6 places)

92 mm

(3.6")

285 mm

(11.2")

RUN

ALT DISP

PAR

ZERO

SPAN

RESET

CLEAR

ENTER

TOTAL

267 mm

(10.5")

Conduit entry area.

Recommend drilling the enclosure with

a hole saw and using suitable cable

glands to maintain ingress rating.

mounting hole

(4 places)

lid

enclosure

customer

mounting screw

Installation

Note: Non-metallic enclosure does not provide grounding between connections.

Use grounding type bushings and jumpers.

Page 6 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 13

Layout

battery,

memory

back up

optional SmartLinx

module*

communications port 3 (RJ-11)

Security

SWI Switch

optional

Analog I/O

board

SHLD

MADE IN CANADA PETERBOROUGH ONT

LCA

LCB

LCCLCD

LOAD CELL INPUTS

V+

S+

S-

EXCITATION

V-

LOAD CELL

SHLD

SIG

COM

CNST

+EXC

SPEED SENSOR

SHLD

MA+

MA-

COM

RS-232

SHLD

AUX1

AUX2

T1+

AUX3

T1-

AUX4

SHLD

T2+

AUX5

T2-

COM

A-Z

SHLD

MILLTRONICS

VENTURE ANALOG I/O

PN ________ -__

VOLT SELECT

200V

50/60HZ

230V

OFF

RLY3

COM

RLY4

RS485

RLY5

SHLD

RLY1

L2/N

RLY2

*To reduce communication interference, route SmartLinx®cable along right side of enclosure wall.

115V

100

Display board

power switch

fuse FU1

Installation

Notes:

• Installation shall only be performed by qualified personnel and in accordance with local governing regulations.

• The Security Switch is shown in its normal position (to the right). When it is in the left position it locks out most keypad functions. See

Security

on page 103.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 7

P350 Calibration

Page 14

WARNING:

• All field wiring must have insulation suitable for at least 250 V.

• Supply dc terminals from SELV source in accordance with IEC 10101-1 Annex H.

• Relay contact terminals are for use with equipment having no accessible live parts and wiring having insulation suitable for at least 250 V.

• The maximum allowable working voltage between adjacent relay contact shall be 250 V.

Software Updates

Note: Contact a Siemens Milltronics representative and get the latest software

revision before upgrading the software in the SF 500.

To update the software you will need:

• Siemens Milltronics Dolphin Plus

• Serial cable to connect a computer and the SF 500

• Software update file

To update the software, follow this procedure:

1. Save the old software to your PC

2. Save the existing parameters to your PC - you may want to print them off for added security

3. Load the new software into the SF 500

4. Perform a master reset (P999)

5. Load the parameters from the file you created in step 2 - alternatively, re-enter them from the parameter print out

When downloading parameters with Dolphin Plus, make sure that the SF 500 is in PROGRAM mode. The zero and span values are included in the parameter file but you should perform new zero and span calibrations to ensure operating accuracy.

Installation

Page 8 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 15

Interconnection

System Diagram

Milltronics

SF 500

optional SmartLinx®

optional analog I/O

fieldbus communication

RS-485

RS-232 / RJ - 11

RS-232

Solids

flowmeter, See

Specifications,

page 3

mA output to customer device

mA input from customer device

relay output, to customer device

auxiliary inputs

customer remote totalizer

optional fieldbus connection

communication ports can be configured for Siemens

Installation

Milltronics Dolphin, print data, or Modbus ASCII or RTU protocol

Note:

• Run wiring via a common conduit

• Do not run wiring in the same conduit as the high voltage contact or power wiring

• Ground shield at one point only. Insulate at junctions to prevent inadvertent grounding.

• Typical system capability. Not all components or their maximum quantity may be required.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 9

Page 16

Flowmeter

One Load Cell

LCA+

LCA-

LCB+

LCB-

SHLD

LCC+

LCC-

LCD+

-LOAD CELL INPUTS-

Two Load Cell

LCD-

SHLD

LCA+

LCA-

LCB+

LCB-

SHLD

LCC+

LCC-

LCD+

-LOAD CELL INPUTS-

LCD-

SHLD

V+

S+

EXCITATION

-LOAD CELL-

SHLD

-LOAD CELL-

S-

V-

SHLD

EXCITATION

load cell

133

V+

S+

S-

V-

customer

junction box

customer

RED

BLK GRN WHT

SHL

SHLDSHLD

RED

BLK GRN

WHT GRN

WHT SHLD

Siemens

Milltronics

solids

flowmeter

load cell A

load cell B

junction box

Where separation between the SF 500 and flowmeter exceeds 150 m (500 ft.):

1. remove the jumpers from SF 500 terminal 11/12 and 13/14

2. run additional conductors from: SF 500 terminal 12 to scale RED

Installation

SF 500 terminal 13 to scale BLK

If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens Milltronics.

Page 10 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 17

LVDT

EXC+ EXC- COM C.T. SIG-

Standard Red Blue Yellow Black Green

Encapsulated Red Orange White Black Yellow

flowmeter with

LVDT

maximum cable run LVDT to Conditioner 300 m (1000 ft.)

Siemens Milltronics

SF 500

Siemens Milltronics LVDT Conditioner

♦Shields are common, but not grounded to chassis. Run cable shields through SHLD terminals and ground at SF 500 only.

If separation between the SF 500 and LVDT conditioner exceeds 150 m (500 ft.):

1. remove the jumpers from SF 500 terminal 11/12 and 13/14

2. run additional conductors from: SF 500 terminal 12 to integrator terminal block ‘+EXC’ SF 500 terminal 13 to integrator terminal block ‘-EXC’

For further connection information on specific LVDTs consult Siemens Milltronics.

Note: A common error is missing the connection from SF 500 terminal 2 to SF 500

terminal 17.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 11

Installation

Page 18

Auxiliary Inputs

Auto Zero

Customer dry contacts, or open collector transistor output supplied as required

Refer to

P270

on page 100 for

programming details.

Prefeed activated dry contact

Refer to

Auto Zero

on page 35.

RS-232 (Port 1)

Printers

Installation

Page 12 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

receive

common

Page 19

Computers and Modems

Typical configurations for connection to a PC compatible computer or modem, using no flow control:

DB-9 DB-25

ComputerModem

RS-485 (Port 2)

Daisy Chain

customer

device

Terminal Device

customer

device

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 13

Installation

Page 20

RS-232 (Port 3)

Note: Jumper pins 4-6 and 7-8 when using hardware flow control. Otherwise, leave

them open.

mA Output 1

to customer instrumentation, isolated mA output, 750 Ω maximum load

Remote Tota lizer

supply, 30V max

remote totalizer 1

Installation

supply,

240V max

remote totalizer 2

Page 14 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 21

Relay Output

The relays are shown in de-energized state. Contacts are normally open, rated 5 A at 250V non-inductive.

Pow er Connections

Notes:

1. The equipment must be protected by a 15 A fuse or a circuit breaker in the building installation.

2. A circuit breaker or switch in the building installation, marked as the disconnect switch, shall be in close proximity to the equipment and within easy reach of the operator.

100 / 115 / 200 / 230V

50 / 60 Hz

select voltage via switch

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 15

Installation

Page 22

mA I/O Board

auxiliary supply output, isolated 24 V dc at 50 mA, short circuit protected

from customer instrumentation, isolated mA input, 200Ω

to customer instrumentation, isolated mA output, 750Ω maximum load

Installing/Replacing the Memory Back-up Battery

The memory battery (3V NEDA 5003LC) has a life expectancy of 10 years. Battery life may be less in cooler climates. In the event that the SF 500 loses external and battery power, a capacitor powers the RAM for approximately 5 minutes.

The SF 500 requires no maintenance or cleaning, other than a periodic replacement of the memory backup battery.

Notes:

Installation

Page 16 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

• Do not install the memory backup battery until the SF 500 is installed, as it begins operation immediately.

• The unit is supplied with one battery. Insert it into the holder as shown below.

Disconnect power before installing or replacing the battery.

Installation Steps

1. Open the enclosure lid.

2. Slide the battery into the holder. Be sure to align the + and – terminals correctly.

3. Close and secure enclosure lid.

Page 23

Installing Optional Plug-in Boards

You can order the following optional plug-ins from Siemens Milltronics:

SmartLinx module

Enhances the existing SF 500 Communications System by providing an interface in one of several popular industrial communications standards.

Analog Input / Output board

The mA I/O board provides 2 programmable 0/4-20 mA outputs, 2 programmable 0/4-20 mA inputs and a nominal 24V dc supply for loop-powered devices.

To Install a Plug-in Board

1. Turn off the power to the SF 500

2. Turn off any power provided to the relay contacts

3. Open the lid

4. Install the plug-in by mating the connectors

5. Secure it in place using the screws provided

6. For the SmartLinx® module only, route the communication cable along the right side of the enclosure wall to reduce interference. Consult the SmartLinx® documentation for any required hardware settings.

7. Close the lid

8. Restore power to the SF 500

SmartLinx

route SmartLinx®cable

along right hand wall

mA I/O board

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 17

Installation

Page 24

Modes of Operation

Display and Keypad

Program

EDIT Mode:

numerical and

arithmetical keys

Press to enter RUN mode

ZERO

SPAN

PAR

RUN

RESET

ALT

CLEAR

ENTER

TOTAL

DISP

Press to enter PROGRAM mode

Press to scroll through RUN displays

RUN

ALT DISP

RUN

ALT DISP

PAR

ZERO

RESET

CLEAR

TOTAL

VIEW Mode:

press to scroll through parameter list

SPAN

Press to alternate

ENTER

between view and EDIT modes, and enter parameter

Press to initiate calibration

values

clear entry

PAR

RESET TOTAL

ZERO

CLEAR

Press to change PID local setpoint values

PID auto/manual

switch

Press to initiate

SPAN

calibration

ENTER

Run

Press to reset

totalizer

The SF 500 has two modes of operation: PROGRAM mode and RUN mode. With the keypad you can operate the SF 500 in either mode, and change between modes.

RUN is the normal or reference mode of operation. It continuously processes the rate signals from the flowmeter to produce internal rate signals. These are used as the basis

Modes of Operation

for totalization (on page 51), mA output, relay control, and communication data. The RUN

Page 18 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 25

display is programmed (P081) to scroll through rate, and totalization (P647), either automatically, or by pressing the enter key.

Rate Total 1 Total 2

becomes

Rate

If the SF 500 is programmed for batch control, the batch display is added to the display scroll. Refer to

Batch Control (P560 - P568

on page 109 and

Batching

on page 66.

Access PROGRAM mode, zero and span calibration from RUN Mode.

PROGRAM mode allows viewing, and with security permission (P000), editing parameter values. While in PROGRAM mode, RUN mode functions are still active, i.e.: rate, relay, mA output and totalization. If PROGRAM mode is left idle for a period of ten minutes, the SF 500 automatically reverts to RUN mode.

Zero and span calibrations effectively halt RUN mode while they are in progress. During this time, totalization ceases, and all mA outputs, except for PID, fall to zero.

Key PROGRAM Mode RUN Mode

4 (EDIT Mode), Scroll Up (VIEW

Mode)

Scroll Up through PID Local Setpoint and Manual Output Values

Scroll Down through PID Local Setpoint and Manual Output Values

Enter PROGRAM Mode

Press either the ZERO key or the SPAN key to initiate Calibration

RUN

PAR

ZERO

8 (EDIT Mode), Scroll Down

(VIEW Mode

Decimal Place Print

- (Dash) Toggle between PID auto/manual

Enter RUN Mode

Press either the ZERO key or the SPAN key to initiate Calibration

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 19

Modes of Opearation

Page 26

Key PROGRAM Mode RUN Mode

SPAN

ALT

DISP

RESET TOTAL

CLEAR

ENTER

Clear Entry

Togg l e b e tw ee n VIEW and EDIT or use to enter parameter values

Scrolls through RUN Displays

Resets Totalizer 1

RUN Mode

To operate the SF 500 in RUN mode, program the unit with the base operating parameters.

If you enter RUN mode before satisfying the program requirements, the PROGRAM routine moves to the first missing item.

PROGRAM Mode

Use PROGRAM mode to change parameter values, and the way the unit operates.

• When the unit is initially powered, it starts in PROGRAM mode

• Ensure that the SW1 is set to the right (see Layout diagram on page 7)

• Program parameters define the calibration and operation of the SF 500

•By entering PROGRAM mode, the user can view the parameter values or EDIT them to suit the application

•When in PROGRAM Mode the unit identifies the name of the parameter, the description, and the options or instructions for making a valid entry

PROGRAM Mode Display

VIEW

P001 Language V 1-Eng 1

EDIT

P001 Language E 1-Eng 1

Modes of Operation

Page 20 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 27

Entering PROGRAM mode

Press

P001 Language V 1-Eng 1

Selecting a parameter:

Scroll:

Press to move up,

P002 Test Reference Selection V 1-Weight, 2-ECal 1

Press to move down.

P001 Language V 1-Eng 1

Accessing a parameter directly:

Press

View/Edit Parameter Enter Parameter Number

The default of previous parameter view is displayed. e.g. P001 is the default parameter for initial start up.

e.g. scrolls up from P001 to P002.

e.g. scrolls down from P002 to P001

e.g. access P011, design rate

Press

P011 Design Rate: V Enter Rate 100.00 kg/h

Or press

P940-2 Load Cell mV Signal Test V mV reading for B 6.78

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 21

in sequence.

For direct access to index parameters

e.g. access P940-2, load cell B mV signal

Modes of Opearation

Page 28

Changing a parameter value:

P011 Design Rate: V Enter Rate 100.00 kg/h

Press

P011 Design Rate: E Enter Rate 100.00 kg/h

Press

P017 Test Rate Weight V

Resetting a parameter value:

Press

P011 Design Rate: E Enter Rate 200.00 kg/h

Press

P011 Design Rate: V Enter Rate 0.00 kg/h

80.00 kg/h

from the view mode

If EDIT mode is not enabled after pressing ENTER, Security is locked. Refer to

Parameters\ Security Lock (P000) on

page 92 for instructions on disabling

Enter the new value

For P0 01 to P017, ENTER completes the change and scrolls to the next required parameter.

from the EDIT mode

Enter the CLEAR function

Value is reset to factory value. e.g. 0.00 kg/h

Modes of Operation

Page 22 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 29

Start Up

Notes:

• For successful start up, ensure that all related system components such as the flowmeter are properly installed and connected.

• Ensure that the SW1 is in the normal position, to the right. (See Layout diagram on page 7)

Initial start up of the SF 500 consists of several stages, and assumes that the physical and electrical installation of the solids flowmeter is complete:

• power up

• programming

• load cell balancing

• zero and span calibration

Power Up

Upon initial power up, the SF 500 displays:

Start Up

P001 Language V 1-Eng 1

The initial display prompts the user to select the preferred language.

Programming

Press

The SF 500 then scrolls sequentially through the start up program as parameters P001 through P017 are addressed.

P002 Test Reference Selection V Select 1-Weight, 2-Ecal 1

Press

P003 Number of Load Cells V Enter (1 or 2) 1

Press

P004 Rate Measurement System V Select 1-Imperial, 2-Metric 2

e.g. Accept ’weight’ (supplied with scale) as the test reference.

e.g. Accept ’1’ as the number of load cells.

e.g. Accept ’2’ for measurements in metric.

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 23

Page 30

Press

P005 Design Rate Units: V Select: 1-t/h, 2-kg/h, 3-kg/min 1

Start Up

Press

e.g. Accept ’1’ for units in t/h

P008 Date: V Enter YYYY-MM-DD 1999-03-19

default date

Press

P008 Date: E Enter YYYY-MM-DD 1999-03-19

Press

e.g. enter current date of October 19, 1999

P009 Time: V Enter HH-MM-SS 00-00-00

factory set time 24 hour clock

Press

P009 Time: E Enter HH-MM-SS 00-00-00

Press

P011 Design Rate: V Enter Rate 0.00 t/h

e.g. enter current time of 14:41

factory design rate

Press

P011 Design Rate: E Enter Rate 0.00 t/h

Press

e.g. rate of 100 t/h

P017 Test rate: Weight MS 1 V Enter test rate 0.00 t/h

Press

P017 Test rate: Weight MS 1 E Enter test rate 0 t/h

e.g. test rate of 75 t/h

Press

This value is obtained from the design data sheet

Page 24 Milltronics SF 500 - INSTRUCTION MANUAL 7ML19985CN01

Page 31

The test rate value should be less than the design rate. If not, contact Siemens Milltronics.

P017 Test rate: Weight MS 1 V Enter test rate 75 t/h

The initial programming requirements are now satisfied. To ensure proper entry of all critical parameter values, return to P002 and review parameters through to P017.

Load Cell Balancing

If you are operating a two-load cell solid flowmeter, balance the load cells electronically. Do this prior to initial programming and calibration, or after either or both load cells have been reinstalled or replaced.

Unbalanced load cells adversely affect the performance of your solids flowmeter weighing system.

Typical two load cell flowmeter

Start Up

load cell

’B’

test weight connection

points

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 25

load cell

’A’

Page 32

Access P295

Start Up

P295 Load Cell Balancing: E Select: 1-A&B 0

Press

Load Cell Balancing A & B Place weight at cell B and press ENTER

test weight

Page 26 Milltronics SF 500 - INSTRUCTION MANUAL 7ML19985CN01

Page 33

Press

Load Cell Balancing A & B Place weight at cell A and press ENTER

Press

Load Cell Balancing A & B Load cells are now balanced.

Start Up

test weight

Balancing the load cell requires a subsequent zero and span calibration

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 27

Page 34

Zero Calibration

Note: To obtain an accurate and successful calibration, ensure that no material is

flowing through the flowmeter and that the test weights are not applied.

Start Up

Press

Zero Calibration: Current Zero 0 Clear flowmeter. Press ENTER to Start

Press

Initial Zero Calibration. In progress Current Reading: #####

The duration of the Zero calibration is dependent upon the present time duration and the (P360) calibration duration.

Press

Calibration Complete. Deviation 0.00 Press ENTER to accept value: 551205

Press

Zero Calibration. Current Zero 551205 Clear flowmeter. Press ENTER to Start

Accepting the Zero returns to start of Zero. Perform a new Zero, or continue to Span.

Span Calibration

the current zero count

the zero count being calculated while calibration is in progress

the deviation from previous zero. For an initial zero there is no previous zero; hence the deviation is 0.

for example, the new zero count, if accepted

the current zero count of 551205

When performing a Span Calibration where the test reference is ECal (P002 = 2), do not apply the supplied test weight and run the flowmeter empty

Note: To obtain an accurate and successful calibration, ensure that there is no

material flowing through the flowmeter and that the test weight is applied.

Stop the material flow and apply the test weight to the flowmeter as instructed in the flowmeter manuals.

Press

Span Calibration. Current Span 0 Setup test. Press ENTER to Start

Page 28 Milltronics SF 500 - INSTRUCTION MANUAL 7ML19985CN01

the current span count

Page 35

Press

Initial Span Calibration. in progress 0 Current Reading ####

the span count being calculated while calibration is in progress

The duration of the Span calibration is dependent upon a preset time duration and the (P360) calibration duration. If P360=1, the span duration is approximately 20 seconds.

Span Count too Low. Press CLEAR to continue.

Press

Calibration Complete. Deviation 0.00 Press ENTER to accept value: 36790

signal from load cell or LVDT too low, ensure proper test weight is applied during calibration

check for proper load cell or LVDT

wiring the deviation from the previous span. For an initial span, there is no previous span count; hence the deviation is 0.

for example, the new span count, if accepted.

Press

Span Calibration. Current Span 36790 Setup test. Press ENTER to Start

for example, the current span count

Accepting the Span returns to start of Span. Perform a new Span or enter RUN mode. Before returning to RUN mode, remove the test weight from the flowmeter and store it in a secure place.

RUN Mode

Start Up

Proper programming and successful zero and span calibration allow entry into the RUN mode. Otherwise, entry is denied and the first missing item of programming or calibration is displayed.

Press

Rate 0.00 kg/h Total 1 0.00 kg

e.g. if there is no material flowing through the flowmeter. The current rate is 0 and no material has been totalized.

Once initial programming is complete and the SF 500 can operate in RUN mode, you may now put the flowmeter into normal service. The SF 500 is functioning under its initial program and calibration, reporting rate of material flow and totalizing.

If the initial entry and operation in RUN mode is successful, recalibrate the weighing system by performing a series of material tests. Material tests verify that the SF 500 is reporting accurately. Where any inaccuracies exist, correct the system with a manual span adjustment (P019).

Perform recalibration of the zero and span routinely to maintain accurate reporting of rate and total.

Refer now to

Recalibration

on page 30.

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 29

Page 36

Recalibration

Material Tests

Perform material tests to verify the accuracy of the span calibration and compensate for material flow. If the material tests indicate a repeatable deviation exists, a manual span adjust (P019) is then performed. This procedure automatically alters the span calibration and adjusts the test rate (P017) value, yielding more accurate span recalibrations.

If the span adjust value is within the accuracy requirements of the weighing system, the material test was successful. Resume normal operation.

Note: Test weights are NOT used during material tests.

If the span adjust value is not acceptable, repeat the material test to verify repeatability. If

Recalibration

the result of the second material test differs considerably, consult Siemens Milltronics or any of its agents.

If the span adjust values are significant and repeatable, perform a manual span adjust.

There are two methods of executing the manual span adjust:

Te st

•

% Change

material and the weight reported by the SF 500 is calculated and entered into P019 as % change.

Material Test:

• P019.

The method of execution is a matter of preference, and yields the same result.

% Change

: based on the material test, the difference between the actual weight of

based on material test, the actual weight of material is entered into

and

Material

% Change

To run a % Change material test:

1. Stop material flow.

2. Perform a zero calibration.

3. Put the SF 500 into RUN mode

4. Record the SF 500 total as the start value _ _ _ _ _ _ (e.g. 17567.0)

5. Run material at a minimum of 50% of design rate for a minimum of 5 minutes.

6. Stop the material feed.

7. Record the SF 500 total as the stop value _ _ _ _ _ _ (e.g. 17995.5)

Subtract the start value from the stop value to determine the SF 500 total

8. Determine the weight of the material sample.

SF 500 total = _ _ _ _ _ _(e.g. 428.5 kg)

material sample weight = _ _ _ _ _ _ (423.0 kg)

Page 30 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 37

Calculate the span adjust value:

% span adjust =

SF 500 – material sample weight

material sample weigh

e.g. (428.5-423.0)x10 0

423

=1.3%

start total

1. z ero cal ibration

x 100

kg / lb

empty scale

Recalibration

2. RUN mode

kg / lb

4. weigh material

3. stop material feed

Access P019 and enter EDIT mode

P019 Manual Span Adjust E Select 1-% Change 2-Material Test 0

Press

P598 Span Adjust Percentage V Enter Calculated +/- error 0.00

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 31

Page 38

Press

P598 Span Adjust Percentage E Enter Calculated +/- error 0.00

Press

if % change is negative, remember to enter the minus sign, e.g. -1.3

P017 Test Rate Weight: MS1 V Enter Test Rate 56.78

Material Test

The Material Test option allows the SF 500 to calculate the size of the material sample as recorded by its totalizers and allows the operator to directly enter the actual weight of the

Recalibration

material sample. The % error is calculated and can be accepted or rejected by the operator.

Access P019 and enter EDIT mode

P019 Manual Span Adjust E Select 1-% Change 2-Material Test 0

Press

Material Test Add to Totalizer 0-No, 1-Yes

Press

e.g. the new test rate value is displayed

if yes, the weight of the material test will be added to the totalizer, if no, material is added to test totalizer (4) only.

Material Test Press ENTER to start

e.g. do not add weight of material test to totalizer

Press

Material Test #.### Press ENTER key to stop

Press

Material Test 964.032

the totalizer reading as the material test is run

e.g. the weight totalized by the solids flowmeter and SF 50 0

Enter actual amount

Press

Material Test Deviation -1.19 Accept 0-No, 1-Yes:

e.g. 975.633 kg is the actual weight of the material test

e.g. the calculated deviation is displayed as a % of the actual weight

Page 32 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 39

Press

P017 Test Rate Weight: MS1 V Enter Test Rate 56.78

Verify the results of the span adjust by material test or return to normal operation.

e.g. the new test rate value is displayed.

Design Changes

Changes to parameters that impact on the calibration do not take effect until a recalibration is done.

If significant changes have been made perform a P377, Initial Zero (see page 34) and/or a P388, Initial Span (see page 37).

Recalibration

To maintain the accuracy of the weighing system, recalibrate the zero and the span periodically. Recalibration requirements are dependent upon the severity of the application. Perform frequent checks initially. As time and experience dictate, reduce the frequency of these checks. Record any deviations for future reference.

The displayed deviations are referenced to the previous zero or span calibration. Deviations are tallied for successive zero and span calibrations. When their limit is exceeded an error message shows that the deviation or calibration is out of range.

Routine Zero

Note: To obtain an accurate and successful calibration, ensure that no material is

flowing through flowmeter and that test weights are not used.

Recalibration

Press

Zero Calibration. Current Zero 551205 Clear flowmeter. Press ENTER to start

Press

Zero Calibration in progress Current Reading: 0.01 kg/m

Calibration complete. Deviation 0.02 Press ENTER to accept value 551418

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 33

e.g. the current zero count

e.g. the rate reported while calibration is in progress

e.g. the calculate deviation in % of full span

e.g. the new zero count, if accepted

if unacceptable, press

to restart

Page 40

Calibration is out of range Deviation report: 403.37

This indicates that the mechanical system is errant. Use P377, initial zero, judiciously and only after a thorough mechanical investigation.

Find and correct the cause of the increased deviation. Then re-try a zero recalibration. If this deviation is acceptable, set P377 to 1 to invoke an initial zero calibration. Further deviation limits are now based on this new initial zero.

Press

Zero Calibration. Current Zero 551418 Clear flowmeter. Press ENTER to start

End of Zero Calibration. Proceed with Span Recalibration or return to RUN.

Recalibration

Initial Zero

Perform an initial zero if necessary when a calibration is out of range message is shown.

Access P377 and enter EDIT mode

P377 Initial Zero E Enter 1 to start initial Zero 0

Press

Zero Calibration. Current Zero 530560 Clear flowmeter. Press ENTER to start

Press

Initial Zero Calibration in progress Current Reading: #####

Calibration complete. Deviation 0.00 Press ENTER to accept value 551413

e.g. zero calibration is accepted and displayed as the current zero

e.g. the current zero

the zero count being calculated while calibration is in progress

e.g. the deviation from the previous zero

e.g. the new zero count if accepted

Press

Zero Calibration. Current Zero 551413

if unacceptable, press to restart

e.g. the current zero count

Clear flowmeter. Press ENTER to start

Note: This is the end of zero calibration. Proceed with zero or span recalibration or

return to RUN.

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Page 41

Direct Zero

Use direct zero entry (P367) when replacing software or hardware, if it is not convenient to perform an initial zero. A record of the last valid zero count is required.

Access P367 and enter EDIT mode

P367 Direct Zero Entry E Enter Zero Count 0

enter the last valid zero count, e.g. 551401

Press

Zero Calibration. Current Zero V Enter Zero Count 551401

e.g. the last valid zero count

Auto Zero

Use Auto Zero to perform a zero calibration automatically when flow stops.

The Auto Zero function provides automatic zero calibration in RUN mode if all of these conditions are met:

• the auto zero input (terminals 29/30) is in a closed state; jumper or remote contact

• the rate of flow is between +2 and -2% of the design rate (P011)

• The terminal and rate status coincide for at least one calibration period (P360)

The rate display is interrupted by the Auto Zero routine

Rate 0.00 t/h Total 1: 0.00 tonnes AZ

Calibration Complete. Deviation 0.0 Auto-Zero value 551410

The duration of the auto zero is one or more calibration periods (P360). If either condition is interrupted during those periods, the auto zero is aborted and the RUN display resumes. There is no loss of totalization. After one calibration period, another auto zero is attempted if the input and rate conditions are met.

(AZ flashes on and off)

e.g. typical zero and deviation values

Recalibration

If the resulting zero deviation is less than an accumulated 2% from the last operator initiated zero, the auto zero is accepted.

If the deviation is greater than an accumulated 2%, an error message is displayed. The error message is cleared after five seconds, however if a relay is programmed for diagnostics, it remains in alarm so long as the Auto Zero conditions are being met.

If material feed resumes during an auto zero function, the zero is aborted and the totalizing function restarts where it left off.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 35

Page 42

Routine Span

Note: To obtain an accurate and successful calibration, ensure that no material is

flowing through flowmeter and the test weight is applied

Press

Recalibration

Span Calibration. Current Span 41285 Setup test. Press ENTER to start

Zero should be done prior to Span Setup test. Press ENTER to start.

Press

Span Calibration in progress Current Reading: 55.56 t/h

Calibration complete. Deviation 0.03 Press ENTER to accept value 41440

Span Count too Low. Press CLEAR to continue.

Calibration is out of range Deviation Error:

e.g. the current span count

do a zero calibration or press

the rate reported while calibration is in progress.

e.g. the deviation from the previous span

e.g. the new span count, if accepted

if unacceptable, press

if the signal from the load cell or LVDT is too low, ensure proper test weight is applied during span

check for proper load cell /LVDT wiring

to restart

This indicates that the mechanical system is errant. Use P388, initial span, judiciously and only after a thorough mechanical investigation.

Find and rectify the cause of the increased or decreased deviation. Then re-try a span recalibration.

If this deviation is still unacceptable, set P388 to 1 to invoke an initial span calibration. Further deviation limits are now based on this new initial span.

Press

Span Calibration. Current Span 41440 Setup test. Press ENTER to start

e.g. span calibration is accepted and displayed as the current value

This is the end of span calibration. Remove the test weight and return to RUN.

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Page 43

Initial Span

Note: Perform an initial span when a calibration out of range message is shown.

Perform a zero calibration prior to performing a span calibration.

Access P388 and enter EDIT mode

P388-01 Initial Span E Enter 1 to start INitial Span 0

Press

Span Calibration. Current Span 41440 Setup test. Press ENTER to start

Zero should be done prior to Span Setup test. Press ENTER to start

Press

Initial Span Calibration in progress Current Reading: #####

Calibration complete. Deviation 0.00 Press ENTER to accept value 41900

Press

Span Calibration. Current Span 41900 Setup test. Press ENTER to start

Remove the test weight and return to RUN.

e.g. the current span count

do a zero calibration or press

the span count being calculated while calibration is in progress

the deviation is reset

e.g. the new span value if accepted

if unacceptable, press

e.g. the current span count

to restart

Recalibration

Direct Span

Direct span entry (P368) is intended for use when replacing software or hardware, and when it is not convenient to perform an initial span. A record of the last valid span count is required.

Access P368 and enter EDIT mode

P368 Direct Span Entry E Enter Span Count 0

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 37

Page 44

Press

Multispan

Recalibration

Connections

P368 Direct Span Entry V Enter Span Count 41900

The SF 500 offers a multispan function. The SF 500 can be calibrated for up to eight different products or feed conditions that produce varying flowrate characteristics. Different feed conditions are typically related to running different materials or multiple feed locations. To accommodate such applications, make a span correction by selecting and applying the appropriate span.

Since every material has its own unique physical properties, and may have a different impact, a span calibration is required for each material to ensure maximum accuracy. With different feeder locations, a span calibration may be required to match each feedpoint or combination of feedpoints.

Each time one of the eight conditions is in effect, select the corresponding multispan prior to putting the SF 500 in RUN mode. Either change the multispan operation number (P365), or program the external contacts connected to the auxiliary input, P270.

To enable multispan operation, address the following:

• connections

• programming

If the span selection is to be done by remote contact, the following connections would apply. Otherwise, no additional connections to the SF 500 are required.

Multispan Selection of Spans 1 and 2 Multispan Selection of Spans 1 to 8

e.g. the last valid span count, e.g. 41900

SHLD

AUX 1

AUX 2

AUX 3

AUX 4

AUX 5

COM

A-Z

*Remote contact can be from relay or open collector switch.

Page 38 Milltronics SF 500 – INSTRUCTION MANUAL 7ML19985CN01

Page 45

Programming Access P365 and enter EDIT mode

P365 Multispan E Select [1-8] 0

Span 1 will have already been set as part of the Start Up and initial calibration. Therefore, select 2.

Access P017 and enter EDIT mode

P017 Test Rate: Weight MS2 E Enter Test Rate 0

Enter the test rate value, and press to do a span calibration.

To do a span calibration for another condition, (i.e. span 3 or 4 etc.), access P365 and repeat these steps for each condition. As with any initial span, follow the span calibration for each multispan with a material test and factoring.

To use remote span selection, auxiliary inputs, 1 and/or 2 or 3, are programmed to read the contact state as the span selection. Remote selection overrides the keypad (or Dolphin Plus) selection. The auxiliary inputs override the keypad selection.

Access P270 and enter EDIT mode

P270-01 auxiliary Input Function E Select Function [0-13] 0

Recalibration

Enter . This programs auxiliary Input 1 (terminal 24) to read the contact state for span

selections: 1 or 2.

Access P270 and enter EDIT mode (when using spans 3 and/or 4)

P270-02 auxiliary Input Function E Select Function [0-13] 0

Enter . This programs auxiliary Input 2 (terminal 25), in conjunction with auxiliary

input 1 to read the contact state for span selections 3 and 4.

Access P270 and enter EDIT mode (when using spans 5 to 8)

P270-03 auxiliary Input Function E Select Function [0-13] 0

Enter . This programs auxiliary input 3 (terminal 26), in conjunction with auxiliary

input 1 and auxiliary input 2 to read the contact state for span selections 5 to 8.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 39

Page 46

Remote selection of a span is not enabled until a span calibration has been done. Initial span selection must be done via the Multispan parameter, P365.

Operation

When span calibration is done, press to revert to the RUN mode.

Recalibration

Rate kg/h 0.00 kg/h MS2 Total 1: 0.00 kg

e.g. if there is no material flowing, the current rate is 0 and no material has been totalized.

When the material to be run changes, the multispan is changed to the corresponding span. This is completed either by changing the span value entered in P365, or by closing

the appropriate contacts connected to the programmed auxiliary inputs.

Multispan

Selection

Aux 3

Span

auxiliary Input

Aux 1

Multispan

Selection Aux 2

If required, reset or note the totalizer value, as the process materials being conveyed may change. Refer to

Totalization (P619-P648)

on page 111.

Linearization applies concurrently to spans.

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Page 47

On-line Calibration

The On-line Calibration feature may be used to routinely check, and if necessary adjust, the Span calibration in RUN mode, without interrupting the material flow.

Install a weigh bin, (bin or silo equipped to

feeder

Max. (e.g. 90%)

High (e.g. 70%)

reference weight: (the amount of material held between High and Low levels)

Low (e.g. 30%)

10 t

Note:

• Press twice, to enter a parameter number directly.

• Whenever you wish to change a value, press to enable the EDIT mode.

provide a 4 to 20 mA output proportional to weight), preceding the material infeed.

Connect the weigh bin to one of the mA inputs on the optional mA I/O board of the Milltronics SF 500: either mA input 1, terminals 5 and 6; or mA input 2, terminals 7 and 8.

Install a material feed control device, preceding the weigh bin.

Recalibration

P355 On-line Calibration Feature E

EDIT mode: value can be changed

Select: 0-Off, 1-On 0

Select the On-line Calibration feature:

Access

P355 On-line Calibration Features V

Value is accepted

Select: 0-OFF, 1-ON 1

Press

Enter the weigh bin reference weight, (the amount of material the bin holds between the High and Low levels), in units selected in P005.

Access

P356 On-line Calibration V Enter Reference Weight 10.000

Press

e.g. reference bin weight

Enter the Max., High, and Low limit setpoints as a percentage in parameter 357.

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Page 48

Recalibration

Access

P357-01 On-line Calibration Limits V MAX Limit: 90.0

limit as a percentage

Press

Access

P357-02 On-line Calibration Limits V HIGH Limit: 70.0

Press

Access

P357-03 On-line Calibration Limits V LOW Limit: 30.0

Press

Calibrate the mA inputs on the SF 500 to the 4 and 20 mA levels of the weigh bin. 4 mA is calibrated with the weigh bin empty, using P261-01 or –02. 20 mA is calibrated with the weigh bin full, using P262-01 and P262-02.

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Page 49

Assign one of the mA inputs for the On-line Calibration function.

Access

P255-01 mA Input Function V Select 0, 1-PID SP, 2-PID FV, 3-OCAL 3

e.g. mA input 1 set to 3

Press

Assign one of the 5 relays, P100-01 to P100-05, to the On-line Calibration function.

Access

P100-01 Relay Function V Select Function [0-9] (see manual) 9

Press

e.g. relay 1 set to 9

Program the assigned relay using P118, relay logic, so that when you connect the assigned relay to the weigh bin material feed control device, the weigh bin material feed stops when the On-Line relay is energized.

Activate On-line Calibration.

Access

P358 On-line Calibration Features V 0-OFF, 1-ACTIVE 1

Press

Note: For remote access, On-line Calibration can also be activated using one of the

auxiliary inputs (refer to

When the On-line Calibration is activated, normal operation continues until the weigh bin fills to the maximum level, (90% in the example shown). During the filling stage, the current level is displayed as a percentage.

On-line Calibration - LOW > 19% Wait for LEVEL > MAX RLY

P270 Auxiliary Input Function

current level displayed as percentage

on page 100).

Recalibration

When the maximum limit is reached, the relay assigned to the On-line Calibration function energizes to stop the weigh bin material feed.

On-line Calibration - 94% > MAX Wait for LEVEL < HIGH RLY 1

Material continues to be discharged from the weigh bin, and when the level drops to the High limit (70% in the example) the On-Line totalizer is automatically activated.

On-line Calibration - TOTAL 3.71 tonnes

running total

Calibration in progress RLY 1

When the Low limit (30%) is reached, the totalizer is deactivated and the assigned relay is de-energized, which reopens the material feed to the weigh bin.

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Page 50

The SF 500 On-line material total, the amount of material totalized between the High and Low limits, is compared to the value entered in P356. The deviation percentage between

these values and the new Span count value is displayed.

Recalibration

On-line Calibration Deviation 2.51% Press ENTER to accept New span 22280

deviation percent

new Span count value

Press to accept the results.

On-line Calibration Complete Press ENTER to accept New span 22280

Note:

• Deviation must be no greater than ± 12% of the initial span or it will not be accepted.

• For remote access, On-line Calibration can be accepted using one of the auxiliary inputs (refer to

P270 Auxiliary Input Function

on page 100).

If you want to reject the results and return to RUN mode, press .

Rate 0.00 t/h Total 1: 10.15 t

Note: For remote access, to return to RUN mode, program one of the auxiliary inputs

(refer to

P270 Auxiliary Input Function

on page 100).

If you want to reject the results and perform another on-line calibration, press return to P358.

Access

P358 On-line Calibration Features V 0-OFF, 1-ACTIVE 1

Press

If the deviation is greater than ± 12%:

Calibration is out of range Deviation Error:

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Page 51

1. Rerun on-line calibration to verify the deviation: press

2. Verify the mechanics of the flowmeter: carry out material tests to ensure the readings are correct. (See page 30,)

3. If the mechanics are functioning correctly, perform an initial span using P388. (See page 37.)

to return to P358.

Factoring

To calculate the value of a new or unknown test weight to the current span, use the factoring procedure.

Note: For optimum accuracy in the factoring results, a routine zero calibration is

recommended prior to performing the factoring routine.

With the material flow turned off:

Access P359 in VIEW mode

P359 Factoring V Enter 1 to start factoring 1

Press

Factoring Weight Place weight and press ENTER.

Press

Factoring Weight Factoring in progress ##.##

Factoring Weight Press ENTER to accept value 45.25

Press

e.g. factor the test weight

the rate reported while factoring is in progress.

e.g. the new factor, if accepted

Recalibration

P359 Factoring: V Enter 1 to start factoring 1

Note: If multispan function is used, the test rate value is stored for the current

multispan only.

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 45

Page 52

Linearization

In applications where the ideal flowmeter location has been compromised, or where there is a high degree of variation in flow rates, the flowmeter may report rate nonlinearly. The SF 500 provides a linearizing function (P390 - P392) to correct for this deficiency in the weighing system and to provide an accurate report of the actual process.

To verify that the cause of the non-linearity is not mechanical:

• Stop the feeding system.

• Remove the flowmeter cover and suspend increasingly heavier test weights to the

If it is determined that the non-linearity is due to the weighing application,

Recalibration

apply linearization by performing the following:

• zero calibration

• span calibration at 90 to 100% of design rate

• material tests at 90 to 100% of design rate

• manual span adjust if required

• repeat material tests at 1 to 5 intermediary flow rates where compensation is

Note: Compensation points must be at least 10% of the design load apart.

sensory mechanism to verify mechanical linearity. For each test weight, note the flow value. If the rate reported by the SF 500 is non-linear, a mechanical problem is indicated. Refer to the flowmeter manual to resolve the non-linearity.

required.

• calculate the percentage compensation for each flow rate tested.

% compensation = (actual weight - totalized weight) x 10 0

Where:

actual weight = material test totalized weight = SF 500 total

totalized weight

Note:

• After programming the compensation into the SF 500, run a material test to verify the effect of linearization.

• If additional compensation is required, it must be based on new material tests performed with the linearization turned off (P390 = 0).

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Page 53

Example:

A non-linearity in the ideal response exists in a solids flowmeter application with a design rate of 200 t/h. Material tests are performed at 15, 30, 45, 60, and 75% of the design rate. Perform a zero and a span calibration at 100% of the design rate, followed by material tests and manual span adjust. The five material tests are performed at 30, 60, 90, 120, and 150 t/h, as indicated by the SF 500. The following data is tabulated. (This example is exaggerated for emphasis.)

SF 500 rate material test SF 500 total compensation*

t/h tonnes tonnes %

30 2.5 2.8 -10.7

60 5.0 4.5 11.1

90 7.5 7.9 -5.1

120 10.0 9.2 8.7

150 12.5 13.3 -6.0

*calculation example: % compensation = 2.5 – 2.8 x 100

2.8

= - 10.7

Recalibration

Weight = tonnes

-5.1

-10.7

-11.1

-6.0

8.7

12030

actual weight per material test totalized weight by SF 500 flowmeter response linearized SF 500 response internal response 100% - 150% of span % compensation span (100%)

150 24060 18090 210

rate t/h

7ML19985CN01 Milltronics SF 500 – INSTRUCTION MANUAL Page 47

Page 54

Recalibration

Program the SF 500 as follows:

Parameter Function

P390 = 1 linearization ON P391-01 = 30 point 1, rate P391-02 = 60 point 2, rate P391-03 = 90 point 3, rate P391-04 = 120 point 4, rate P391-05 = 150 point 5, rate P392-01 = - 10.7 point 1, compensation P392-02 = 11.1 point 2, compensation P392-03 = - 5.1 point 3, compensation P392-04 = 8.7 point 4, compensation P392-05 = -6.0 point 5, compensation

Note: Often only one point of compensation is required, usually at a low rate

value. In the prior example, if compensation was only required at 30 t/h, program the following parameters. Optimize compensation by establishing the next rate value that agrees with the material test, the compensation is zero and is entered as the next compensation point.

P390 = 1 linearization on P391-01 = 30 point 1, rate P391-02 = 90 point 2, rate P392-01 = -10.7 point 1, compensation P392-02 = 0 point 2, compensation

actual weight per material test

Weight = tonnes

-10.7

12030

totalized weight by SF 500 flowmeter response linearized SF 500 response internal response 100% - 150% of span % compensation span (100%)

150 24060 18090 210

rate t/h

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Operation

Rate Sensing

For the SF 500 to calculate rate and totalize material flow through the flowmeter, a rate signal representative of material flow is required. The rate signal is provided by the flowmeter. The SF 500 is compatible with flowmeters fitted with one or two strain gauge type load cells. To function with LVDT type sensors, an optional LVDT conditioning card is required.

Specifications

Refer to page 9 for the proper connection.

Damping

Damping (P080) provides control over the speed at which the displayed rate reading and output functions respond to changes in the internal rate signals. The damping controls change in the displayed rate of material flow. Relay alarm functions based on input functions of rate respond to the damped value.

Damping consists of a first order filter applied to the signal (reading or output value).

If mA damping (P220) is enabled (value other than 0), then the damping (P080) as it pertains to the mA function is overridden, and responds independently at the specified

mA output damping rate (P220).

on page 3 for flowmeter requirements, and

Interconnection

Operation

Note: Damping (P080-01 or P220) is not applicable to the mA output when

programmed for PID function (P201 = 2).

mA I/O (0/4-20 mA)

Output

The standard SF 500 provides one isolated mA output (P201). The output range can be set to 0 - 20 mA or 4 - 20 mA (P200). The 0 or 4 mA value corresponds to no flow or zero condition, whereas the 20 mA value corresponds to the associated design rate (P011). The mA output can be limited for over range levels of 0 mA minimum and 22 mA maximum (P212 and P213 respectively). The output 4 and 20 mA levels can also be trimmed (P214 and P215 respectively) to agree with a milliamp meter or other external mA device.

The mA output value can be tested to output a prescribed value using parameter P911.

P911 mA Output Test

Refer to

The optional mA I/O board provides two additional mA outputs, programmable as outputs 2 and 3, using the same parameters as the standard output (1). If programmed for PID

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 49

on page 116.

Page 56

control, output 2 is assigned to PID control loop 1 and output 3 is assigned to PID control loop 2.

Input

The optional mA I/O board provides two mA inputs, programmable as inputs 1 and 2. If programmed for PID control, assign input 1 to PID control loop 1 and input 2 to PID control loop 2.

The input range can be set to 0-20 mA or 4-20 mA (P250), and assigned a function (P255), e.g. PID setpoint. The 4 and 20 mA levels can be trimmed (P261 and P262) to agree with an external device.

Relay Output

The SF 500 offers five single pole single throw (SPST) relays that can be assigned (P100) to one of the following alarm functions:

• rate: relay alarms on high and/or low material flow rate.

• diagnostic: relay alarms on any error condition as it is reported.

• PID: PID control setpoint deviation*

• batch pre-warn

• batch setpoint

*is offered only if the PID system (P400) is enabled.

For rate alarm functions, enter the high and low alarm setpoints (P101 and P102

Opearation

respectively) in the appropriate units. The high alarm setpoint acts as the setpoint deviation alarm for relays programmed for PID setpoint deviation.

The on/off actuation at both high and low setpoints is buffered by the damping (P080) and the programmable dead band (P117), to prevent relay chatter due to fluctuations. The relay is normally energized; holding the normally open (n.o.) contact closed (can be programmed for reverse operation, P118). In an alarm condition, the relay is de-energized and the relay contact is opened. Once in alarm, the relay remains in alarm state until the alarm condition is removed.

Example: P011 = 360 t/h P100 = 1-rate P101 = 100% (360 t/h) P102 = 20% (72 t/h) P117 = 2% (7.2 t/h)

Alarm is ON with relay de-energized.

Refer to

Troubleshooting

on page 118.

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Totalization

The totalization function is based on the internal rate (mass per unit time) signal proportional to flow rate and load on the associated flowmeter. It is not affected by the damping function (P080). The rate signal is sampled several times a second to accurately count the mass of material conveyed. The count is held in the master totalizer used to increment the internal totalizers and to produce a pulse signal for the remote totalizers.

The SF 500 provides several separate totalizer functions:

Internal totalizers

• local display (totalizers 1 and 2)

• verification totalizer (totalizer 3)

• material test totalizer (totalizer 4)

• batch total (totalizer 5)

External totalizers

• totalizer outputs (remote totalizers 1 and 2)

To avoid totalizing material at flow rates below the low flow rate limit, the totalizer drop out limit (P619) is set to a percentage of the design load. Below this limit, totalization stops. When material flow returns to a rate above the drop out limit, totalization resumes.

Totalizer resolution or count value is set by the respective internal (P631) and external (P638) totalizer resolution parameters.

e.g.: Internal totalizer 1

Given: P005 = 1 (t/h)

P631 = 4

Operation

Then: totalizer count increments by 10 for each 10 metric tonnes registered

External totalizer 1

Given: P005 = 1 (t/h)

P638 = 5

Then: contact closure occurs once for every 10 metric tonnes registered

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Page 58

For remote totalization, the contact closure duration (P643) is automatically calculated upon entry of the design rate (P011) and remote totalizer (P638) parameters, so that the duration of contact closure allows the relay response to track the total up to 150% of the design rate. The value can be changed to suit specific contact closure requirements, such as in the case of programmable logic controllers. If the duration selected is inappropriate, the next possible duration is automatically entered.

The totalizers are reset through the master reset (P999), the totalizer reset (P648) or through the keypad.

• master reset: the reset of all totalizer functions is included in the master reset.

• totalizer reset: totalizer reset can be used to resets internal totalizers 1 and 2, or totalizer 2 independently. Resetting the internal totalizers 1 and 2 resets the internal registers for external totalizers 1 and 2.

• keypad: pressing

while in the RUN mode resets internal totalizer 1

Placing the internal totalizers on to the display scroll of the RUN mode is controlled by the totalizer display parameter (P647). This displays either one or both totalizers.

Opearation

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Page 59

PID Control

The PID control algorithm in the SF 500 works for feed rate control applications. It is based on motor control type algorithms and includes several anti-windup provisions.

To operate the SF 500 as a controller, address the following:

• hardware

• connections

• setup and tuning

• programming

Hardwar e

For the SF 500 to operate as a controller, install the optional mA I/O board. Refer to

Interconnection

Connections

In addition to the standard operating connections, make connections to the process instruments.

Refer to:

Interconnection

•

Relay Output

•

mA I/O Board

•

Auxiliary Inputs

on page 9.

on page 9, specifically:

for relay connections on page 15

on page 16, for mA input and output connections

on page 12, for optional remote control

Connect the SF 500 as either a:

1. setpoint controller – rate control

2. setpoint controller – external process variable with or without rate control

PID loop mA output

1 21 & 215 & 6

2 33 & 427 & 8

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 53

terminals

(mA I/O)

mA input

terminal (mA I/O)

PID Control

Page 60

Setpoint Controller – Rate Control

screw conveyor

process variable (rate)

RUN PAR ZERO SPAN

RESET

ALT

ENTERCLEAR

TOTAL

DISP

PID O/P demand rate

optional remote setpoint

Parameter Index Choices

01 02 03

Controller Selection P400- 1

Process Variable Source P402-

Setpoint Configuration P414-

mA O/P Function P201-

mA I/P Function P255-

Figure A

motor speed

controller

impact force

---- 0=Off, 1=Man, 2=Auto

1=Rate, 2=mA I/P 1,

---3=mA I/P 2

0=Local, 1=mA I/P 1,

---2=mA I/P 2

1=Rate, 2=PID

0=Off, 1=PID Set-

----

point, 2=PID Process Var iab le

PID Control

*Set to 1 for Remote Setpoint operation

Default Value =

Comments:

1. Connect signal to controlled device to mA O/P 2

2. For Remote Setpoint (optional). Connect remote 4-20 mA setpoint to I/P mA 1

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Page 61

Setpoint Controller – Rate and Additive Control

Figure B

liquids flowmeter

rotary feeder (primary product)

additive product

pump

flow (PV)

motor

speed

controller

motor

speed

controller

PID-02 O/P

PID-01 O/P

rate (PV)

to mixing device

Parameter Index Choices

01 02 03

Controller Selection P400- 1

Process Variable Source P402-

Setpoint Configuration P414-

mA O/P Function P201-

mA I/P Function P255-

Remote Ratio P418-

Default Value =

Comments:

1. Connect primary rate controlled device to mA O/P 2 Connect additive rate controlled device to mA O/P 3 Connect additive process variable to mA I/P

Hardwire mA O/P 1 to mA O/P 2

100f100

RUN PAR ZERO SPAN

RESET

ALT

ENTERCL EAR

TOTAL

DISP

---- 0=Off, 1=Man, 2=Auto

1=Rate, 2=mA I/P 1,

----

3=mA I/P 2 0=Local, 1=mA I/P 1,

---2=mA I/P 2

1=Rate, 2=PID

0=Off, 1=PID Set-

----

point, 2=PID Process Var iab le

---- Setpoint=% of input

PID Control

2. Ratio of Additive to Primary product may be adjusted by changing P418-02

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 55

Page 62

Setpoint Controller – Master/Slave Control

Figure C

rotary feeder

motor

SLAVE - additive

process variable (rate)

RUN PAR ZERO SPAN

ALT DISP

speed

controller

RESET

ENTERCLEAR

TOTAL

PID-01 O/P

drag conveyor

PID-01 O/P

PID Control

MASTER - primary product

process variable

(rate)

optional remote setpoint

Page 56 Milltronics SF 500 - INSTRUCTION MANUAL 7ML19985CN01

RUN PAR ZERO SPAN

RESET

ALT

TOTAL

DISP

ENTERCLEAR

motor speed

controller

rate O/P

Page 63

SF 500 - Master

Parameter Index Choices

Controller Selection P400- 1

Process Variable Source P402-

Setpoint Configuration P414-

mA O/P Function P201-

mA I/P Function P255-

Remote Ratio (optional) P418-

01 02 03

100f100

---- 0=Off, 1=Man, 2=Auto

1=Rate, 2=mA I/P 1,

---3=mA I/P 2

0=Local, 1=mA I/P 1,

---2=mA I/P 2

1=Rate, 2=PID

0=Off, 1=PID Set-

----

point, 2=PID Process Var iab le

---- Setpoint=% of input

Default Value =

Comments:

1. Connect Rate output of SF 500-Master mA O/P 1, or mA O/P 3 to mA I/P 1 of SF 500-Slave Connect signal to controlled device from mA O/P 2

2. For Remote Setpoint on Rate Control (optional) Connect remote 4-20 mA setpoint to mA I/P 1 Ratio of Primary product to remote setpoint may be adjusted by changing P418-01

SF 500 - Slave

Parameter Index Choices

01 02 03

Controller Selection P400- 1

Process Variable Source P402-

Setpoint Configuration P414-

mA O/P Function P201-

mA I/P Function P255-

Remote Ratio (optional) P418-

100f100

---- 0=Off, 1=Man, 2=Auto

----

---- Setpoint=% of input

1=Rate, 2=mA I/P 1, 3=mA I/P 2

0=Local, 1=mA I/P 1, 2=mA I/P 2

1=Rate, 2=PID

0=Off, 1=PID Setpoint, 2=PID Process Var iab le

PID Control

Default Value =

Comments:

1. Connect primary rate controlled device to mA 2 O/P

2. Ratio of Additive to Primary product may be adjusted by changing P418-01

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Page 64

Setup and Tuning

Before proceeding, it would be beneficial to qualify and quantify the terms you will encounter in the setup and tuning of the control system.

Proportional Control (Gain), P

The P term adjusts the control output, based on the difference between the set point and the measured flow rate. A higher P term increases the sensitivity of the SF 500 unit, allowing it to react more quickly to changes or disturbances. If set too high, the SF 500 becomes less stable, and more susceptible to oscillations in the control output.

• allowable input range: 0.00 0 to 2.000

• typical operating range: 0.300 to 0.600

• default value: 0.400

The control output cannot reach the setpoint using only the P term. Since the P term acts on the difference between the setpoint and process variable, a small difference between these two always exists. The difference is never zero. A small P term can get the process very close to set point, but this takes a long time. At minimum, an I term is required to eliminate the offset created by the P term.

Integral Control (Automatic Reset), I

The I term on the SF 500 is used to increase or reduce the amount of control output to eliminate the offset caused by the P term. The I term acts on the accumulation of the error over small increments of time. As the process reaches setpoint and the error becomes small, the effect of the I term decreases. A higher I term allows the SF 500 to react to changes faster, but can also make it less stable.

• allowable input range: 0.00 0 to 2.000

• typical operating range: 0.100 to 0.300

• default value: 0.200

The P and I terms together can make a suitable control algorithm and for many applications, they work fine. However, if faster response to changes is desired, it is necessary to use larger P and I terms. Unfortunately, larger terms can make the system unstable. A derivative term is needed to influence the control output as the process

PID Control

variable approaches the set point.

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Derivative Control (Pre-Ac t or Rate), D

The D term on the SF 500 influences the control output based on changes in the magnitude and direction of the change in error. If there is a constant error, the D term has no effect. As the error gets larger, the D term combines with the P term to make the SF 500 control output respond faster. When the error is getting smaller, the D term acts to reduce the amount of control output to help prevent overshooting the set point. In general, a higher P term requires a larger D term.

Error

Decreasing Error

Direction of Proportional Action

Direction of Derivative Action

Increasing Error

Decreasing Error

Increasing Error

• allowable input range: 0.00 0 to 1.000

• typical operating range: 0.010 to 0.100

• default value:0.050

The result of the derivative action is that it can make a system more responsive and more stable at the same time.

Feed Forward Control, F

The F term is used to adjust the control output based on a setpoint change. The use of this term can make the system reach the new setpoint faster. If the term is not used, the system responds using the P, I, and D terms only. The difference between the new setpoint and the process variable is the error and the control algorithm responds to eliminate this new error.

When the F term is used and a new setpoint is entered, a proportion of the difference between the new setpoint and the process variable is automatically added on to the control output. This shifts the process variable closer to the new setpoint faster than using the P, I, and D terms alone. This is done on a one-time basis.

• allowable input range: 0.00 0 to 1.000

• typical operating range: 0.250 to 0.550

• default value: 0.300

Setpoint

PID Control

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Page 66

The PID control function of the SF 500 can be configured to operate in several modes.

• controller output: direct acting

• feedback: rate, load or external

• control: local or remote (ratio) setpoint

PID Setup and Tuning

Proper tuning of the control PID terms is essential to system operation and optimum performance from the feeder. The recommended procedures for tuning the PID control terms at initial startup are described in this section.

Notes:

• Meet Zero and Span criteria

• Set controller (P400=1) to manual and adjust the output for 0% flow (using the 4 and 8 keys). Material must not flow through flowmeter.

• Shut off the prefeed to, or ensure that no material is fed into the flowmeter.

Initial Start Up

Although the default values of the P, I, D, and F terms suit the majority of applications, some tuning is necessary.

There are several techniques and procedures for tuning conventional PID controllers. Some work better depending upon the application. We recommend using closed-loop cycling for the SF 500 integrator/controller for feed rate control. First, tune the P term while disabling the I and D terms. Then add and tune the I term, and then the D term.

To outline this procedure:

1. With the P term set to its default value of 0.400, disable the I, D and F terms by setting them to 0.000.

2. Enter a feed rate setpoint that is 30% of the designed maximum flow rate.

3. Start the pre-feeder and observe the time it takes the pre-feeder to reach setpoint. Observe the oscillation around setpoint.

4. Adjust the P term accordingly for consistent oscillation and error. Progressively decrease the P term value if there is too much oscillation and error. Likewise, increase the value if the error is not consistent and oscillating around the setpoint.

PID Control

Page 60 Milltronics SF 500 - INSTRUCTION MANUAL 7ML19985CN01

Refer to fig 1, 2, and 3 below.

Page 67

Figure 1

SETPOINT

Figure 2

SETPOINT

P term is too high

P term is too low

Figure 3

SETPOINT

P term is correctly set

5. Once the P term value is set to give the control output of the SF 500 consistent oscillation and the error is at its minimum, turn the pre-feeder off.

6. The I term value can now be set. Begin by entering the default value of 0.2.

7. Restart the pre-feeder (test weights or chains still applied) and feed rate setpoint entered.

8. Again observe the oscillation of the control output. Compare results to the figures 4,5 and 6 below.

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 61

PID Control

Page 68

Figure 4

Figure 5

SETPOINT

I term is too high

Select manual to program PID parameters.

I term is too low

Figure 6

SETPOINT

I term is correctly set

PID Control

9. The D term is not critical in most pre-feeder applications. The purpose of the D term is to anticipate where the process is heading by looking at the time rate and direction of change of the process variable. The D term becomes very useful in applications where the material control point is far away from the measuring point, e.g. a long screw feeder more than a few seconds process time from the flowmeter.

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Page 69

A properly set D term makes the initial oscillations around the setpoint smaller, as in figure 6. A D term set too high induces high oscillations, as in figure 4. Omission of the D term, or set too low, shows no effect on the system.

10. The above closed loop cycling procedure allows ease in start up, but final adjustments may be necessary in actual process operation.

Programming

The SF 500 must be programmed to take advantage of the PID algorithms.

The SF 500 offers programming for two separate PID controls, 1 and 2. The controller being programmed is identified by the index to the parameter number. E.g. P400-01 indicates that PID for control system 1 is accessed.

Note: All programming should be done in the PID manual mode.

Access

P400-01 PID System E Select: 0-Off, 1-Manual, 2-Auto 0

Off disables the PID parameter set, P401 to P418. They are not accessible.

Manual: the control output is the manual output P410.

Auto: engages the PID controller function. This can also be done using the key.

To program PID parameters, select 1-Manual.

Note:

For the mA output:

• mA output 2 (P201-02) is normally reserved for controller 1. The signal is output at terminals 1 and 2 on the mA I/O board.

• mA output 3 (P201-03) is normally reserved for controller 2. The signal is output at terminals 3 and 4 on the mA I/O board.

P201-02 mA Output Function E Select: 1-Rate, 2-PID 1

Select the PID function.

Note:

For the mA input:

• mA input 1 is an external signal normally reserved for controller 1. The signal is input at terminals 5 and 6 on the mA I/O board.

• mA input 2 is an external signal normally reserved for controller 2. The signal is input at terminals 7 and 8 on the mA I/O board.

PID Control

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Page 70

P250-01 mA Input Range E Select 1- 0 to 20, 2-4 to 20 2

Select the appropriate range for the mA input signal

P255-01 mA Input Function E Select: 0, 1-PID SP, 2-PID PV 0

P401-01 PID Update Time E Readings between PID Updates 1

P402 Process Variable Source E 1-Rate, 2-mA In1, 3-mA In 2

P405-01 Proportional Te rm E Enter 0.40

P406-01 Integral Term E Enter 0.2

P407-01 Derivative Term E Enter 0.05

P408-01 Feed Forward Term E Enter 0.3

Assign either:

1, PID setpoint, or 2, process variable as the function of the mA input

Enter the value, e.g. nominal value of 1

Select the source. Rate is an internal values.

Enter the value for the proportional term, e.g. nominal value of 0.4

Enter the value for the integral term, e.g. nominal value of 0.2

Enter the value for the derivative term, e.g. nominal value of 0.05

Enter the value for the feed forward term, e.g. nominal value of 0.3

P410-01 Manual Mode Output E Current Output Value 0

P414-01 Setpoint Configuration E

PID Control

0-Local, 1mA In 1, 2-mA In 2 0

Local: the setpoint is the value entered into P415.

% value of output during manual operation, P400 = 1

Selection of setpoint source:

0 = local (keypad or Dolphin Plus) 1 or 2 = mA input

mA Input 1: the setpoint is the mA value on input 1, terminals 5 and 6 on the mA I/O board.

mA Input 2: the setpoint is the mA value on input 2, terminals 7 and 8 on the mA I/O board.

P415-01 Local Setpoint Value E Enter Setpoint 0

Enter the setpoint value in engineering units.

Not applicable if P414 = 1 or 2

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P416-01 External Setpoint E Setpoint 0

Current setpoint value in engineering units, obtained from the mA input

P418-01 Remote Setpoint Ratio V Enter % of Master Output 100.000

P250-01 mA Input Range E Select 1- 0 to 20, 2-4 to 20 2

P255-01 mA Input Function E Select 0, 1-PID SP, 2-PID PV 0

Increase or decrease to scale input setpoint, if desired.

Select the appropriate range for the mA input signal

Assign either:

1. PID setpoint, or

2. process variable as the function of the mA input

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 65

PID Control

Page 72

Batching

The batching process, as it relates to the SF 500 operation, can be defined as the transfer of a predetermined quantity of material.

The process supports a count up operation (P560), in that the total (totalizer 5) begins at zero and increments up to the programmed setpoint (P564). A relay (RL1 through 5) programmed as the batch setpoint function (P100 = 8) is actuated when the material total reaches the setpoint. The relay contact acts as an interlock to the material feed to end the batch.

Another relay can be programmed as a pre-warn alarm (P100 = 7), to alert the process that batch end is near. The relay is actuated when the material total reaches the prewarn setpoint (P567) at some practical value below the batch setpoint). The pre-warn function is enabled / disabled from the batch process through P566.

For batch operations, the following must be addressed:

• connections

• programming

•operation

Connections

Typical Ladder Logic

SF 500 / RL1*

batch stop

47 48

stop

start

motor contactor /

MC1

SF 500 / RL2*

pre-warn

MC1

SF 500/

batch reset

* Typical relay assignment. Relays 1-5 are available for batch setpoint or pre-warn alarm function.

♦

Typical auxiliary input assignment.

Batching

aux 1

♦

RUN

ALT DISP

PAR

ZERO

RESET

CLEAR

TOTAL

♦

SPAN

ENTER

Inputs 1- 5 are available for batch reset.

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alarm

Page 73

Programming

The pre-warn function is optional.

The setpoint associated with the pre-warn relay is entered in P564, batch setpoint.

The setpoint associated with the batch relay is entered in P567, batch pre-warn setpoint.

Batch Operation

Access P560 Batch Mode Control Select 1, enable batch operation Access P564 Batch Setpoint Enter the desired batch total Access P566 Batch Pre-warn Set to ON (1) or leave it OFF (0) If batch pre-warn is selected, access P567

Batch Pre-Warn Setpoint Access P568 Batch Pre-act Set to OFF (0) or AUTO (1) or manual (2)

Relays

Access P100, Relay Function

Access P100 Relay Function

Enter the Pre-warn total

Select relay (1 – 5) Select function 5, Pre-Warn

Select relay (1-5, other than the pre-warn relay)

Select function 6, Setpoint

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Batching

Page 74

Operation

Once the SF 500 relays are connected to the process logic and it is programmed, the SF 500 is ready for totalizing the batch and stopping the process when the batch setpoint is reached. The batch operations start, pause, resume, and cancel are controlled externally by the process control (e.g. PLC)

Place the unit in the RUN mode.

Press until the batch screen is displayed.

Rate 0.00 kg/h SP: 20.000 Batch 0.00 kg

Start running the batch.

The display will show the rate of material flow and the batch total, as well as the batch setpoint. If pre-warn is used, relay contact is open.

When the batch total reaches the pre-warn setpoint, if programmed, the alarm event is removed and the assigned relay contact is closed.

Rate 123.4 kg/h SP: 20.000 Batch 17.00 kg ALM 1

The process continues. When the batch total reaches the batch setpoint, the alarm event is displayed and the assigned relay is actuated (contact opened). Typically the relay contact would be integrated into the batch control logic to end the process.

Rate 123.4 kg/h Batch 20.00 kg ALM 12

When the next batch is to be run, pressing and then on the local keypad, or providing a momentary contact closure across an auxiliary input (programmed as batch

reset, P270 = 8), sets the alarm display and resets the batch total to zero, and the relay contact to its closed state.

Rate 0.00 kg/h SP: 20.000 Batch 0.00 kg

e.g relay 1 is programmed for pre-warn, P100-1 = 5

e.g. relay 2 is programmed for batch setpoint, P100-2=6

Note: The batch totalizer can be viewed as a read-only parameter (931-05), using

single Parameter access through any programmed communication port.

Pre-act Function

If repetitive batches are being run, the pre-act function (P568) can be enabled to automatically trip the setpoint relay before or after the batch setpoint is reached in order to assure best batch accuracy.

Batching

Or, in manual mode, enter a set value to cause the batch setpoint to pre-act at a designed accumulation.

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Communications

The SF 500 is an sophisticated flow meter integrator that can communicate status back to a SCADA system using a serial device such as radio modems, leased lines, or dial up modems.

radio modem

Communications

RUN PAR ZERO SPAN

RESET

ALT

ENTERCLEAR

TOTAL

DISP

dial-up modem

leased line modem

The SF 500 supports two protocols: Dolphin and Modbus. Dolphin is a proprietary Siemens Milltronics protocol designed to be used with Dolphin Plus. Modbus is an industry standard protocol used by popular SCADA and HMI systems.

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SF 500 and SmartLinx

In addition to three onboard communication ports, the SF 500 is compatible with Siemens Milltronics SmartLinx industrial communication systems.

This section only describes the onboard communications. For more information on

Communications

SmartLinx

Connection

There are three serial communication ports on the SF 500:

Refer to

communication modules which provide an interface to popular

, please consult the appropriate SmartLinx® manual.

WARNING: When a SmartLinx® card is installed and P799 = 1 (Communications Control parameter), the parameters that the SmartLinx updated. Therefore, if you connect a SmartLinx

card is writing to the SF 500 will be continuously

card to the SF 500, set P799 = 1 and not write anything to the SmartLinx your setpoints will be 0.

Port Description

Installation

RS-232, Terminals 31 to 34

RS-485, terminals 41 to 46

RS-232, RJ-11 modular telephone jack

on page 6 for wiring diagrams specific to each port.

card,

Wiring Guidelines

Improper wiring and choice of cables are the most common sources of communication problems. Listed below are some suggested guidelines:

• 15 meters (50 feet) for RS-232

• 1200 meters (4000 feet) for RS-485

• Ensure that communication cable is run separately from power and control cables (i.e. do not tie wrap your RS-232 cable to the power cable or have them in the same conduit).

• cable is shielded and connected to ground at one end only

• 24 AWG (minimum)

• follow proper grounding guidelines for all devices on the bus

• use good quality communication grade (shielded twisted pairs) cable that is recommended for RS-232.

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Configuring Communication Ports

The SF 500 communications ports are setup by a series of parameters (P770 – P789) which are indexed by port.

The communication parameters are indexed to the following:

Port Description

indicates the factory setting.

Note: Changes to these parameters do not take effect until the power to the unit is

cycled.

P770 Serial protocols

The communications protocol used between the SF 500 and other devices for the selected port, ports 1 to 3 (P770-01 to –03).

The SF 500 supports Siemens Milltronics’ proprietary Dolphin data format plus the internationally recognized Modbus standard in both ASCII and RTU formats. It also supports direct connection of a printer.

The Siemens Milltronics protocol is compatible with the Dolphin Plus configuration program. See the Siemens Milltronics web site for information on this PC product (http://www.siemens-milltronics.com/).

The Modbus protocol is an open standard developed by AEG Schneider Automation Inc. Specifications are available from their web site (http://www.modicon.com/).

Other protocols are available with optional SmartLinx

RS-232, Terminals 31 to 33

RS-485, terminals 41 to 45

RS-232, RJ-11 modular telephone

cards.

Communications

Values

0 communications disabled 1 Siemens Milltronics "Dolphin" protocol 2 Modbus ASCII slave serial protocol 3 Modbus RTU slave serial protocol 4printer

f /-01 and -02

f l-03

Note: SF 500 must be in RUN mode to allow for the print operation.

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P771 Protocol address

Note: Applicable only to ports programmed for Modbus RTU or Modbus ASCII

(Parameter 770).

The unique identifier of the SF 500 on the network for the selected port, ports 1 to 3 (P77101 to -03).

Communications

For devices connected with the Siemens Milltronics protocol this parameter is ignored.

For devices connected with a serial Modbus protocol this parameter is a number from 1-

247. It is up to the network administrator to ensure that all devices on the network have

unique addresses.

Do not use the value 0 for Modbus communications as this is the broadcast address and is inappropriate for a slave device.

Values

0 to 9999 (f = 1)

P772 Baud Rate

The communication rate with the master device for the selected port, ports 1 to 3 (P77201 to –03).

The baud rate chosen should reflect the speed of the connected hardware and protocol used.

Values

1 4800 baud 2 9600 baud 3 19,200 baud

-01 and -02

f-03

P773 Parity

The serial port parity for the selected port, ports 1 to 3 (P773-01 to –03).

Ensure that the communications parameters are identical between the SF 500 and all connected devices.

e.g many modems default to N-8-1 which is No parity, 8 data bits, and 1 stop bit.

Values

0none 1even 2odd

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P774 Data bits

The number of data bits per character for the selected port, ports 1 to 3 (P774-01 to –03).:

Protocol P744 Value

Modbus RTU

Modbus ASCII

Dolphin Plus

7 or 8

Note: Use 8 data bits when using port 2.

Values

5 to 8 (f = 8)

P775 Stop bits

The number of bits between the data bits for the selected port, ports 1 to 3 P775-01 to -03).

Values

1 or 2 (f = 1)

Communications

P778 Modem attached

Sets port 1 (P778-01) to use an external modem.

Any connected modem must be set up to auto-answer incoming calls. The SF 500 does not automatically configure the modem.

Autobaud (enabled by P778=1)

When the SF 500 is powered up or the P779 Modem Inactivity Timeout expires three carriage returns are sent to the modem to allow it to set its serial connection to P772 Baud Rate.

If a connection is made with the modem at a different baud rate the SF 500 will attempt to use that rate instead of the P772 value. For troubleshooting purposes the baud rate on the modem can be hard-coded to the rate set on the SF 500. See your modem documentation for information on fixing the baud rate.

Val ues

0 1 modem connected

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 73

no modem connected

Page 80

P779 Modem idle time

Sets the time in seconds that the SF 500 will keep the modem connected even though no activity is happening.

To use this parameter ensure that P778=1.

This parameter allows for reconnection to the SF 500 unit after an unexpected

Communications

disconnect. Ensure that the value is low enough to avoid unnecessary delays when an unexpected disconnect occurs but long enough to avoid timeout while you are still legitimately connected.

Hanging Up

If the line is idle and the P779 Modem Inactivity Timeout expires then the modem is directed to hang up the line. This is done with the Hayes commands:

• two second delay

• +++

• two second delay

•ATH

Ensure that P779 is set longer than the standard polling time of the connected master device.

0 disables the inactivity timer.

Values

0-9999: 0 (f = 1)

P780 RS-232 Transmission interval

Note: Applicable only to ports programmed for printer communication

(parameter 770).

Sets the interval between transmissions to be applied to the selected port, ports 1 to 3 (P780-01 to –03).

Enter the period in minutes. (

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= 0)

Page 81

P781 Data message

Note: Applicable only to ports programmed for printer communication (parameter

770).

Sets the data message to be delivered via the selected port, ports 1 to 3 (P781-01 to -03).

All messages and printouts include time and date.

Entry:

0 = no message 1 = rate 2 = total* 3= rate and total* 4 = batch total (totalizer 5) 5 = quick start parameters (P001 – P017) 6 = all parameters

*totalizer 1 and/or 2 as set by P647, Totalizer Display

P799 Communications Control

Communications

Assigns programming control either locally through the keypad or Dolphin Plus (P770 = 1), or remotely through Modbus protocol (P770 = 2 or 3) or SmartLinx

Entry:

0 = local 1 = remote

WARNING: When a SmartLinx® card is installed and P799 = 1, the parameters that the SmarlLinx be continuously updated. Therefore, if you connect a SmartLinx card to the SF 500, set P799 = 1 and not write anything to the SmarLinx

card, your setpoints will be 0.

card is writing to the SF 500 will

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Page 82

Dolphin Protocol

The protocol is available on all communications ports on all units. This protocol is not available for third party use.

The primary use of this protocol is to connect the SF 500 to Siemens Milltronics’ Dolphin Plus configuration software.

Communications

Dolphin Plus Screen Shot

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Page 83

Modbus RTU/ASCII Protocol

Modbus is an industry standard protocol owned by Schneider Automation Inc.1 and is used throughout process control industries for communication between devices. Modbus RTU and Modbus ASCII are both master-slave type protocols. SF 500’s Modbus is a slave unit.

SF 500 supports both the RTU and ASCII version of Modbus and attempts to automatically detect the type when a connection is made.

A brief description of Modbus RTU and Modbus ASCII is given in this manual. For a full description of the Modbus protocol, contact your local Schneider representative. Also you may try their website at http://www.modicon.com.

Note: Siemens Milltronics does not own the Modbus RTU protocol. All information

regarding that protocol is subject to change without notice.

How Modbus Works

As mentioned above, Modbus is a master-slave type protocol. This can also be referred to as a query-response protocol. What both of these terms mean is that on the network, there is one master which requests information from multiple slave devices. The slave devices are not permitted to talk unless they have been asked for information. When responding, the slaves will either give the information that the master has requested or give an error code consisting of why it can not give the information or that it did not understand the request. Refer to

All SF 500 information is mapped into the Modbus holding registers so that Modbus function code 03 can read from them and Modbus function code 06 and 16 can write to them.

Error Handling

on page 90.

Communications

Modbus RTU vs. ASCII

There are two main differences between Modbus RTU and Modbus ASCII. The first is that Modbus RTU encodes the message in 8-bit binary, while ASCII encodes the message in ASCII characters. Therefore, one byte of information would be encoded into 8 bits for RTU and into two ASCII characters for ASCII (which would be two 7-bit units). The second difference is that the error checking method is different (see below).

Modbus RTU has the advantage that it has a much greater data throughput than ASCII. Modbus ASCII has the advantage that it allows time intervals of up to one second to occur between characters without causing an error. Either protocol works with the SF

500.

Modicon is a registered trademark of Groupe Schneider.

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Page 84

Modbus Format

Note: When using a commercial Modbus driver all of the message details are

handled for you.

To give you a better idea of how a Modbus message works, a master on network would send a message in a format similar to this:

Communications

Where:

Station address the network address of the slave being accessed

Function Code number that represent a Modbus command, either:

Information depends on function code

Error Check Cyclical Redundancy Check (CRC) for RTU and Longitudinal

There is more to the frame than is described above, this is shown to give the user a general idea of what is going on. For a full description, refer to the Modbus specifications.

Station

address

Function

code

Information

03 read function 06, 16 write functions

Redundancy Check (LRC) for ASCII

Error

check

Modbus Register Map

The memory map of the SF 500 occupies the Modbus holding registers (R40,001 and up).

The SF 500 makes it easy for users to get useful information via Modbus. The following chart gives an overview of the different sections.

Map Legend Description

Type Arbitrary classification of registers.

Description Brief description or title of associated register.

Start

Number R

Parameter Values Refer to

Read Identifies the read / write capability for the register being addressed.

Reference Provides reference documentation for the register being addressed.

Page 78 Milltronics SF 500 - INSTRUCTION MANUAL 7ML19985CN01

Provides the starting address for the register(s) where the parameter values are to be read from or written to.

The number of registers required to read or write the complete parameter value. Where the number of registers (6) are addressed in incrementing sequence from the start register.

Param eter Valu es

, page 87.

Page 85

Type Description Start # R

Format

Handshaking

Area

(Parameter

Access)

Date and Time

Process Values

I/O

Diagnostic Diagnostic State 41,200 1 number code r see page 95

Format Word for 32 bit variables

ID Device Identifier 40,064 1 2 r see page 80

Parameter 40,090 1 0-999 r/w Primary Index 40,091 1 0 - 9 r/w Secondary Index 40,092 1 0 - 9 r/w Format Word 40,093 1 bit mapped r/w Read Value (word 1) 40,094 2 32 bits r Write Value (word 1) 40,096 2 32 bits r/w YYYY 41,000 1 1996-2069 r/w MM 41,001 1 1 - 12 r/w DD 41,0 02 1 1 - 31 r/w hh 41,0 03 1 00 - 23 r/w mm 41,004 1 00 - 59 r/w ss 41,005 1 00 - 59 r/w

Time Zone 41,006 1 -12 - 12 r/w

Rate 41,010 2 32 bits r

Total 2 41,018 2 32 bits r Device State 41,020 1 bit mapped r see page 84 Command Control 41,022 1 bit mapped r/w see page 85

Multi-Span Selection 41,024 1 1 - 8 r/w

Total 1 decimal places 41,025 1 1 - 3 r/w see page 85 Total 2 decimal places 41,026 1 1 - 3 r/w see page 85 PID 1 Setpoint 41,040 2 32 bits r/w PID 2 Setpoint 41,042 2 32 bits r/w

Batch Setpoint 41,044 2 32 bits r/w

Batch Prewarn Setpoint 41,046 2 32 bits r/w

Discrete Input 41,070 1 bit mapped r Relay Outputs 41,080 1 bit mapped mA Inputs 41,090 2 0000 - 20,000 r mA Outputs 41,110 3 0000 - 20,000 r

40,062 1 0 - 1 r/w see page 80

Parameter

Values

Read Reference

see page 80

see P008

page 94 and

page 83

see P009

page 94 and

page 83 see P739 page 114

see page 84Total 1 41,016 2 32 bits r

see page 38 and P365 on

page 104

see P416 page 109 see P564 page 109 see P567 page 110

see page 86

Communications

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 79

Page 86

Type Description Start # R

PID 1 Proportional Term 41,400 2 32 bits r/w PID 2 Proportional Term 41,402 2 32 bits r/w PID 1 Integral Term 41,404 2 32 bits r/w PID 2 Integral Term 41,406 2 32 bits r/w PID 1 Derivative Term 41,408 2 32 bits r/w

Communications

PID Tuning

PID 2 Derivative Term 41,410 2 32 bits r/w PID 1 Feed Forward Term 41,412 2 32 bits r/w PID 2 Feed Forward Term 41,414 2 32 bits r/w PID 1 Remote Setpoint Ratio PID 2 Remote Setpoint Ratio

Modbus Register Map (cont’d)

Format (R40,062)

This value determines the format of all unsigned, double-register integers (UINT32), except for those in the direct parameter access.

0 indicates that the most significant byte (MSB) is given first 1 indicates that the least significant byte (LSB) is given first

For more information on this data format see page 87

Device Identifier (R40,064)

Parameter

Values

41,416 2 32 bits r/w

41,418 2 32 bits

Read Reference

r/w

see P405 page 107

see P406 page 108 see P407 page 108 see P408 page 108

see P418 page 109

This value identifies the Siemens Milltronics device type and is “2” for the SF 500.

Handshaking Area (Parameter Access)

An advanced handshaking area is built into the SF 500. Use it to read and write 32 bit parameters.

Mapping Parameter Read and Write (40,090 – 40,095) is a series of six registers that are used for reading and writing parameter values to and from the SF 500. The first three registers are always unsigned integers representing parameters and index values. The second three registers are the format and value(s) of the parameter.

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Page 87

All parameters normally accessed through the hand-held programmer are available through these registers.:

Address Description

40,090 Parameter (integer)

40,091 Primary Index (integer)

40,092 Secondary Index (integer)

40,093 Format word (bit mapped)

40,094 Read value, word 1

40,095 Read value, word 2

40,096 Read value, word 1

40,097 Read value, word 2

Reading Parameters

To read parameters through Modbus follow these steps:

1. Send the parameter, its primary index, and its secondary index (usually 0) and format to registers 40,090, to 40,093.

2. Wait until you can read the above values from the registers (40,090 to 40,093).

3. Read the value from registers 40,094 and 40,095.

Writing Parameters

To set parameters through Modbus follow these steps:

1. Send the parameter, its primary index, and its secondary index (usually 0) to registers 40,090, 40,091, and 40,092.

2. Write the value to registers 40,096 and 40,097

3. Write the desired format word to register 40.093 to enable the SF 500 to interpret the value correctly.

Communications

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Page 88

Communications

Format Register:

Bits Values Description

1 - 8 0 - 2 Error Code

9 - 11 0 - 7 decimal offset*

12 0/1 decimal shift*, Right (0) or Left (1)

13 0/1 Numeric format: Fixed (0) or FLoat (1)

14 0/1 Read or Write of data, Read (0), Write (1)

15 0/1

16 Reserved

The bits listed above are in order from least to most significant:

15 14 13 12 11 1 0 987654321

*For example, to format the level reading so that it is shown in percent with two decimal places shifted left the format bits would look like this:

15 14 13 12 11 1 0 987654321

001001000000000

Word order: Most Significant word first (0), Least Significant Word first (1)

reserved

read

fixed format

most significant first

decimal offset of +2

no error code

The value sent to the SF 500 is 0001001000000000 binary or 4608 decimal. The value 4608 is sent as an integer to register 40,093 to format the output words 40,094 and 40,095 accordingly.

If the numeric data type is set for integer and the value contains decimal places, they are ignored. In this situation use the decimal offset to ensure that you have an integer value and then write your code to recognize and handle the decimal offset. Bits 9 to 11 indicate the number of place by which the decimal is to be shifted. Bit 12 indicates the direction by which the decimal point is shifted, left or right. For example, if the decimal offset (value of bits 9 to 11) is ‘2’ and the shift (value of bit 12 is ‘0’), then the decimal point is shifted two places to the right.

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Page 89

Error Codes

The error codes returned in the format area are 8-bit integers found in the lowest 8 bits of the format word. This allows for 256 potential error codes.

Currently the SF 500 has two error codes available:

Values Description

0No error

1 Data not available as percent (available as units)

2-255 Reserved

Date and Time (R41,000 – 41,006)

The date and time can be read or written in registers 41,000 to 41,006 as defined in the table above.

Example: If you are located in Toronto, Canada and would like to set the date and time to February 14, 1999, 1:30 p.m. and 42 seconds, you would write the following:

Bits Values

R41,000 1999

R41,001 2

R41,002 14

R41,003 13

R41,004 30

R41,005 42

R41,006 -5

Communications

Note: The time zone register is used only as a reference and does not affect the

operation of the SF 500.

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Page 90

Process Values (R41,010 – R41,048)

Rate and Total (R41,010 – R41,019)

The associated registers provide the readings of rate. Totalizer 1 and Totalizer 2 in engineering units as displayed in the local SF 500 display.

Device State (41,020 – 41,020)

Communications

The Device State word is used to feedback the current operating state of the product. Each bit gives the state of different parts of the product, some mutually exclusive, others are not. The state should be checked to verify any device commands.

Bit # Description Bit Clear Bit Set (1)

1 PID 1 Mode Manual Auto

2 PID 1 Freeze No Ye s

3 PID 1 Setpoint Source Local Remote

4 PID 2 Mode Manual Auto

5 PID 2 Freeze No Yes

6 PID 2 Setpoint Source Local Remote

7 Zero No In progress

8 Span No In progress

9---

10 - - -

11---

12 - - -

13 Write Privileges No Yes

14 System Configured Not Configured Yes

15 Mode Calibration Mode RUN Mode

16 To t a li z in g Not Totalizing To t al i z in g

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Page 91

Command Controls (41,022 – 41,022)

The command control word is used to control the unit. Each bit gives access to a command or state as if the operator was using the keypad.

Bits initiating a command (7-12) must change state in order to cause the command the begin. For example, to reset totalizer 1, Bit 9 must be set to 0, then changed to 1. It can stay set or clear for any period:

Bit # Description Bit Clear Bit Set (1)

1 PID 1 Mode Manual Auto

2 PID 1 Freeze No Ye s

3 PID 1 Setpoint Source Local Remote

4 PID 2 Mode Manual Auto

5 PID 2 Freeze No Yes

6 PID 2 Setpoint Source Local Remote

7 Zero No change Start

8 Span No change Start

9 Reset Totalizer 1 No change Reset

10 Reset Totalizer 2 No change Reset

11 Reset Batch Totalizer No change Reset

12 Print - Print

13---

14 - - -

15---

16 - - -

Communications

Note: Set parameter P799 for remote control before commanding the SF 500 remotely.

Read/Write (R41,025 – R41,026) Total Decimal Places

Sets the number of decimal places (0-3) being read for Total 1, (words 41,016 and 41,017) and Total 2, (words 41,018 and 41,019).

With 3 decimal places, the largest value that can be read is 2,147,483.648. With 2 decimal places, the largest value that can be read is 21,474,836.48. With 1 or 0 decimal places, the largest value that can be read is 100,000,000.

Example: R41,025

Bits 0 and 1 are used to indicate the number of decimal places being read in Total 1, Words 7 and 8.

Bit 15 is used to indicate if the decimal place is too large to read the total value correctly.

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If three decimal places are being read in Total 1:

Bits 15 14 13 12 11 1 0 9876543210

If three decimal places are being read in Total 1, and the value is too large to be read with three decimal places:

15 14 13 12 11 1 0 9876543210

Bits

Communications

I/O (R41,070 – 41,116)

The SF 500 provides I/O in the form of:

• discrete inputs

• relay outputs

•mA inputs*

•mA outputs*

* The standard SF 500 provides only one mA output (0/4 – 20 mA). The inclusion of an optional mA I/O card provides two mA inputs (0/4 – 20 mA) and two additional mA outputs.

For the I/O, the assigned registers represent the logic status (e.g. open or closed) of the I/ O as configured. Discrete inputs are configured via P270, auxiliary input function; while relay outputs are configured via P100, relay function.

The I/O are mapped into the respective input and output registers, R41,070 and R41,080, as follows:

0010010000000011

1010010000000011

R41,070 R41,080

Input Bit Output Bit

11 1 1

2 2 2 2

33 3 3

4 4 4 4

55 5 5

For the mA I/O, the assigned registers represent the mA level (e.g. 0 to 20 mA) of the I/O as registered in P911 and P914, mA output test (output value) and mA input value.

The mA I/O are mapped into the respective input and output registers:

Input Register Output Register

1 R41,090 1 R41,110

2 R41,091 2 R41,111

3 R41,112

For 0 to 20 mA I/O, the register value ranges from 0 to 20,000. For 4 to 20 mA I/O, the register value ranges from 4,000 to 20,0 00. If the 4 or 20 mA values have been trimmed,

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Page 93

then the register value is adjusted accordingly; e.g. an I/O value of 22 mA would be registered as 22,000.

Diagnostic (R41,200)

Refer to

Troubleshooting

on page 118.

PID Tuning (R41,400 – 41,419)

For SF 500 set up for PID control, several registers have been provided for tuning. Refer to

PID Control

on page 53 and the associated parameters as listed in the register map.

Note: Before you can change any of the setpoints, P799 must be set for remote

control.

Parameter Values

Bit Mapped

Bits are packed into registers in groups of 16 bits (1 word). In this manual we number the bits from 1 to 16, with bit 1 being the least significant bit and bit 16 referring to the most significant bit.

16 15 14 13 12 11 1 0 987654321

MSB LSB

32 Bit

Large numbers are put into unsigned 32 bit integers with a fixed decimal place of three. For example, a value of ‘7345’ represents a value in the SF 500 ‘7.345’. The default word order is that the first word is the most significant word (MSW) and the second word (register) is the least significant word (LSW).

For example, if we read R41,431 as a 32-bit, the 32 bits would look like the following:

Communications

R41,431

16 MSB 1 16

32 32-bit integer value (UNINT32)

The whole is read as a 32-bit integer.

To accommodate some Modbus drivers, the most significant byte (MSB) and least significant byte (LSB) can be reversed. See Format Word for SF 500 on page 80 for details.

7ML19985CN01 Milltronics SF 500 - INSTRUCTION MANUAL Page 87

R41,432

LSB 1

Page 94

Text Messages

If a Siemens Milltronics device parameter returns a text message, that message is converted to a number and provided in the register. The numbers are shown in the table below:

Communications

Number Text Message as Displayed on LCD

22222 invalid value

30000 OFF

30001 ON

30002 = = = =

30003 (parameter does not exist)

30004 err

30005 err1

30006 open

30007 shrt

30008 pass

30009 fail

30010 hold

30012 hi

30013 de

30014 en

-32768 value is less than -20,000

32767 value is greater than 20,000

Modems

The SF 500 has been successfully connected to several different modems. In general, the Modbus protocol is a very modem friendly protocol. This section gives some general guidelines on modems and their connection. For detailed information, see the modem documentation.

Picking Modems

There are several different types of modems; dial-up, leased line, radio-link, fiber-optic to name the most common.

Dial-up

uses a standard analog phone line and dials the number of the receiving modem.

Lease line

come in either 2 or 4 wire types and use special phone lines that are ‘leased’ from your phone company (or you) and do not require any dialing.

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Radio-link

come in many different types, but all use radio frequencies for transmitting the information.

Fiber-optic

uses a fiber-optic line to connect the two modems.

Each type of modem and each model have various characteristics. Before purchasing the modem contact the modem manufacturer and ask if they have had experience using the modems with Modbus protocol with no flow control. If they have, ask them what settings were required.

Setting up the Modems

Configure modems using software, dip switches, jumpers or a combination. Dip switches are normally located at the back of the modem, jumpers are normally located on the motherboard and require that you remove the cover. Software normally requires you to use a standard terminal program and to connect to the RS-232 port on the modem and send special commands. The most popular command set is called the AT, or Hayse, command set.

For a typical dial-up modem, try the following setup as a first attempt:

Master

Modem

• auto answer off (dip switch?)

• load factory default (dip switch?)

• no flow control (dip switch?)

• baud rate = 9600

• 10 data bits (probably the default)

Communications

Modbus RTU Software

• baud rate = 9600

•8 bit

• no parity

•1 stop bit

• dial prefix: ATDT

• Initialization command: ATE0Q0V1X05=0512=100

• Reset command: ATZ

• Hang-up command: ATHO

• Command response delay: 5 seconds

• Answer Delay: 30 seconds

• Inter-character delay: 55 ms

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Slave

Modem

• auto answer on (dip switch)

• load factory default (dip switch)

• no flow control (dip switch)

• baud rate = 9600

Communications

• 10 data bits (probably the default)

SF 500

• set P770, port 1, to the value 3 (Modbus RTU)

• set P771, port 1, to the value 1 (Network ID 1)

• set P772, port 1, to the value 3 (Baud rate of 9600)

• set P773, port 1, to the value 0 (No Parity)

• set P774, port 1, to the value 8 (8 Data Bits)

• set P775, port 1, to the value 1 (1 Stop Bit)

• set P778, port 1, to the value 1 (Communications through Modem)

• set P779, port 1, to the value 300 (Modem Inactivity of 300 seconds)

Note: Parameters are defined in the Installation section (page 6).

Error Handling

Modbus Responses

When polled by a Modbus Master, a slave device will do one of the following:

1. Not reply. This means that something went wrong with the transmission of the message.

2. Echo back the command with the correct response. This is the normal response. (see the Modbus specifications for more details).

3. Return an Exception Code. This reflects an error in the message.

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SF 500 uses the following exception codes:

Code Name Meaning

01 Illegal Function

02 Illegal Data Address

03 Illegal Data Value

04 Slave Device Failure

05 Acknowledge

06 Slave Device Busy

08 Memory Parity Error

The function code received in the query is not an allowable action for the slave.

The data address received in the query is not an allowable address for the slave.

A value contained in the query data filed is not an allowable value of the salve.

An unrecoverable error occurred while the slave was attempting to perform the requested action.

The slave has accepted a request and is processing it, but a long duration of time is required.

The slave is processing a long-duration program command.

The slave attempted to read extended memory, but detected a parity error in the memory. Service may be required on the slave.

Error Handling

Errors can be divided up into two general sources. Either:

1. There is an error in transmission

2. The user tries to do something that is not a valid action

Communications

In the first case, the SF 500 will, not respond and let the master wait for a response time out error, which will cause the master to re-send the message.

In the second case, it depends on what the user tries to do. Listed below are various actions and what the expected outcome is. In general, SF 500 will not give an error to the user request.

• If the user reads an invalid parameter, the user will get a number back.

• If the user writes an invalid parameter (a non-existing parameter or a read only parameter), the value will be ignored and no error response will be made. However, the current value will not reflect the desired new value.

• If the user writes a read only register, then the value will be ignored and no error response will be made. However, the current value will not reflect the desired new value.

• If the user attempts to write one or more registers that are out of range, an exception response code 2 will be generated.

• If using an unsupported function code, undocumented results may occur. The user is encouraged not to do this.

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Parameters

indicates factory set value

P000 Security Lock

Locks out the program editor so that parameter values for P001 through P999 cannot be changed. This however does not prevent the access to the parameters for viewing.

Programming is locked out if the value of P000 is other than 1954.

Entry:

1954 = unlocked 1954 = locked

Parameters

Start Up (P001 to P017)

This is the minimum parameter programming required before attempting a calibration and successful entry into the RUN mode.

P001 Language

Selects the language for communication with the SF 500

Entry:

1 = english

Note: This manual only lists English as a choice of language. However, your SF 500

will list the additional languages of choice, as the translated software is made available.

P002 Test Reference Selection

Selects the type of test reference used to represent a material rate: weight or electronic.

weight: the weight that is supplied specific to the flowmeter

electronic: calibration based on automatic calculation of the mV span from the load

cells or LVDT

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Entry:

1 = weight 3 = ECal

P0 03 Number of Load Cells

Siemens Milltronics flowmeters are available in models of one or two load cell design. Select the number of load cells corresponding to the flowmeter connected.

If using the optional remote LVDT conditioner card, for LVDT based scales, select the “1” value.

Entry:

Enter the number of load cells: 1f or 2.

P004 Rate Measurement System

Selects system of measurement used, either imperial or metric.

Entry:

1 = imperial 2 = metric

P005 Design Rate Units

Determines the units for programming and measurement.

imperial - P004 = 1 metric - P004 = 2

1f=

entry:

Changing this parameter does not affect the rate parameter (P011). This parameter should be re-entered for conformity in units.

2 =

3 =

4 =

T/h (tons / hour) t/h (tonnes / hour)

LT/h (long tons / hour) kg/h (kilograms / hour)

lb/h (pound / hour) kg/min (kilograms / minute)

lb/min (pounds / minute)

Parameters

t = 1000 kg LT= 2240 lb. T= 2000 lb.

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P008 Date

Enter the current date in

Where:

yyyy = year mm = month, 01 –12 dd = day, 01 – 31

e.g. 1999-03-19 (March 19, 1999)

P009 Time

Enter the current time in

Where:

Parameters

hh = hour mm = minute ss = second

P011 Design Rate

Specifies the design rate of material flow for the flowmeter. (f = 0.00)

Enter the design rate from the supplied design data sheet, in the units selected (P005).

P017 Test Load

yyyy-mm-dd

hh-mm-ss

, 24 hour format.

format.

The rate referenced when performing a span. (f = 0.00)

Enter the test rate value as shown in the corresponding solid flowmeter instruction manual.

P019 Manual Span Adjust

Provides a means for adjustment to the span calibration. (f = 0)

The adjustment value is determined by performing material tests and is subsequently entered either as a calculation of % change into P598, or as the weight of the material test.

Entry:

1 = % change 2 = material test

Recalibration

Refer to

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on page 30.

Siemens Milltronics SF 500 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Milltronics SF 500

Milltronics SF 500 features

The Manual

Specifications

Installation

Dimensions

Layout

Software Updates

Interconnection

System Diagram

Flowmeter

One Load Cell

Two Load Cell

LVDT

Auxiliary Inputs

Auto Zero

RS-232 (Port 1)

Printers

Computers and Modems

RS-485 (Port 2)

Daisy Chain

Terminal Device

Remote Tota lizer

Relay Output

Pow er Connections

mA I/O Board

Installing/Replacing the Memory Back-up Battery

Installing Optional Plug-in Boards

To Install a Plug-in Board

Modes of Operation

Display and Keypad

RUN Mode

PROGRAM Mode

PROGRAM Mode Display

Entering PROGRAM mode

Start Up

Power Up

Programming

Load Cell Balancing

Typical two load cell flowmeter

Zero Calibration

Span Calibration

RUN Mode

Recalibration

Material Tests

% Change

Material Test

Design Changes

Recalibration

Routine Zero

Initial Zero

Direct Zero

Auto Zero

Routine Span

Initial Span

Direct Span

Multispan

On-line Calibration

Factoring

Linearization

Operation

Rate Sensing

Damping

mA I/O (0/4-20 mA)

Output

Input

Relay Output

Totalization

PID Control

Hardwar e

Connections

Setpoint Controller – Rate Control

Setpoint Controller – Rate and Additive Control

Setpoint Controller – Master/Slave Control

SF 500 - Master

SF 500 - Slave